Manual de Operação e Manutenção SY500H

Quality Changes the World
Crawler Hydraulic
Excavator
SY500H
Operation and Maintenance Manual

SY500H Hydraulic Excavator
SY500H
Hydraulic Excavator
Operation and Maintenance Manual
WARNING
Please read and follow the safety precautions and instructions in this manual and on the
machine nameplate. Otherwise, severe injuries, deaths or property loss may occur. Please
keep this manual together with the machine for future reference.
Operation and Maintenance Manual-12-2015 1

2 Operation and Maintenance Manual-12-2015

Sany Group
Sany Heavy Machinery Limited.
Sany Industrial Park, Dongcheng avenue, Kunshan Economic Development Zone,
Jiangsu, China
Zip code: 215300
Service hotline: 4008 28 2318
Inquiring and Complaint Number: 4008 87 9318
http: //www.sanygroup.com
© 2015 by Sany Group. All rights reserved. No part of this publication may be
reproduced, used, distributed or disclosed except during normal operation of the
machine as described herein. All information included within this publication was
accurate at the time of publication. Product improvements, revisions, etc., may result in
differences between your machine and what is presented here. Sany Group assumes
no liability. For more information, contact Sany Group.


Responsibility Division
Important statements
The crawler hydraulic excavator is a multipurpose machine for earthwork construction, intended
for earth excavation and loading, land leveling, slope finishing, hoisting, crushing, demolition,
ditching, and widely applied in highway and railway construction, bridge construction, urban con-
struction, and construction of airports, ports and water conservancy. The machine has the features
of bulldozers, loaders and cranes, and can replace them during operation. The machine is not in-
tended for other purposes than those designated. We do not accept any responsibility for any con-
sequence of use for purposes other than those designated.
We do not accept any responsibility for the following:

• Consequences of failure to correctly use the machine according to the instructions in the
manual.
• Consequences of unauthorized retrofitting or modification of the machine.
• Equipment damage or accidents caused by failure to use genuine accessories or use of un-
tested or unauthorized accessories or tools.
• Machine faults or damage because of nature disasters (earthquakes, typhoons, etc.), wars and
other force majeure.
We cannot foresee all risks that may occur at the working site; therefore, the machine operators
and customers shall pay high attention to safety issues.
The regions where the machine is used and their local governments may have more strict operat-
ing provisions which shall be observed if they conflict with these rules for safe operation.
Responsibilities of our manufacturer
• Ensure that the machine quality is acceptable and accompanying documents are accurate.
• Fulfill the after-sales service commitment, and document all the maintenance and repair work
performed by after-sales service personnel.
• Provide trainings to the equipment operators and maintenance staff as required.
Responsibilities of customers or other authorized personnel concerned
• Personnel concerned shall be welled trained and fully acquainted with the Parts Catalogue and
the Operation and Maintenance Manual before operating and maintaining the machine.
• Make sure that personnel operating and maintaining the machine are competent and aware of
their respective responsibilities.
• Regularly inspect the safety awareness of personnel concerned in working.
• Immediately stop the machine in the event of any fault influencing safety.

• Our service personnel have the right to carry out the relevant safety check on the machine when
necessary.
• Besides checks specified by Sany, carry out the relevant inspection according to the related reg-
ulations by the country or region where the machine is used.
• Make sure that the machine is timely maintained and repaired.
• Make a use planning carefully and consciously.
Responsibilities of all the operation personnel
• In the event of any abnormalities that may cause abnormal operation of the machine or pose a
potential risk, timely report to the supervisor, and rectify in time if possible.
• All staff working around the machine must obey all the warning signals and caution for safety of
themselves and others.
• All the operation personnel shall be acquainted with the content and procedures of work
activities.
• Observe whether there are dangerous situations such as high voltage wires, irrelevant person-
nel, poor ground condition, and timely warn the operators and signalmen of them.
Responsibilities of management
Make sure that only operators that are well trained, fully understand the content of this manual, en-
joy good health and possess the operation certificate can operate the machine.
• Make sure that only operators with good judgment, cooperation consciousness and psychologi-
cal quality can operate or maintain the machine.
• Make sure that signalmen have good visual and audible judgment, know well standard com-
manding signals and send clear and accurate signals, and possess rich experience in hazard
identification and instruct operators to avoid in time.
• Make sure that assistants can correctly determine the machine model and working condition,
and choose an appropriate machine.
• Assign the corresponding safety responsibility to each operation personnel and ask them to
timely report unsafe factors to the supervisor.

SY500H Hydraulic Excavator Table of Contents
Table of Contents
1 Foreword..............................................................................................................................1-1
1.1 General ...................................................................................................................................1-3
1.2 Safety information .................................................................................................................1-4
1.3 Page description....................................................................................................................1-6
1.4 Introduction ............................................................................................................................1-6
1.4.1 General ..........................................................................................................................1-6
1.4.2 Directions of the machine............................................................................................1-7
1.4.3 Running-in of new machines ......................................................................................1-7
1.5 Product information...............................................................................................................1-8
1.5.1 General ..........................................................................................................................1-8
1.5.2 Machine data plate .......................................................................................................1-8
1.5.3 Engine data plate..........................................................................................................1-8
2 Safety.....................................................................................................................................2-1
2.1 Safety decals .........................................................................................................................2-5
2.1.1 General ..........................................................................................................................2-5
2.1.2 Location .........................................................................................................................2-6
2.1.3 Description.....................................................................................................................2-7
2.2 Safety information .............................................................................................................. 2-13
2.2.1 Safety rules................................................................................................................. 2-13
2.2.2 Handling of abnormalities......................................................................................... 2-13
2.2.3 Personal protective equipment................................................................................ 2-14
2.2.4 Fire extinguisher and first-aid kit ............................................................................. 2-15
2.2.5 Safety equipment....................................................................................................... 2-15
2.2.6 Keeping the machine clean...................................................................................... 2-16
2.2.7 Keeping the cab clean .............................................................................................. 2-16
2.2.8 Locking of safety lock control lever ......................................................................... 2-17
2.2.9 Armrest and ladder.................................................................................................... 2-17
2.2.10 Precautions for working at heights........................................................................ 2-18
2.2.11 Keeping clear of the accessory ............................................................................. 2-18
2.2.12 Don’t get stuck in the articulation section ............................................................ 2-18
2.2.13 Preventing scald...................................................................................................... 2-19
2.2.13.1 Hot coolant........................................................................................................ 2-19
2.2.13.2 Hot oil................................................................................................................. 2-20
2.2.14 Fire and explosion prevention ............................................................................... 2-21
2.2.14.1 Fire caused by fuel or engine oil .................................................................... 2-21
2.2.14.2 Fire caused by inflammable materials .......................................................... 2-22
Operation and Maintenance Manual-12-2015 I

Table of Contents SY500H Hydraulic Excavator
2.2.14.3 Fire caused by electrical wire......................................................................... 2-22

2.2.14.4 Fire caused by hydraulic circuit...................................................................... 2-22
2.2.14.5 Fire caused by lighting equipment................................................................. 2-22
2.2.14.6 Fire caused by heat shield.............................................................................. 2-22
2.2.15 Actions in case of a fire........................................................................................... 2-22
2.2.16 Windshield cleaning solution ................................................................................. 2-23
2.2.17 Preventing flying components ............................................................................... 2-23
2.2.18 Prevent falling, flying and invading objects ......................................................... 2-23
2.2.19 Accessory installation ............................................................................................. 2-24
2.2.20 Accessory combination .......................................................................................... 2-24
2.2.21 Cab window glass ................................................................................................... 2-24
2.2.22 Unauthorized retrofit ............................................................................................... 2-24
2.2.23 Site survey in advance ........................................................................................... 2-25
2.2.24 Operation on loose ground .................................................................................... 2-26
2.2.25 Don’t approach high voltage cable ....................................................................... 2-27
2.2.26 Ensuring favorable view ......................................................................................... 2-28
2.2.27 Ventilation of working environment....................................................................... 2-29
2.2.28 Prevention of asbestos dust .................................................................................. 2-29
2.2.29 Cab emergency exit ................................................................................................ 2-30
2.3 Safe machine operation .................................................................................................... 2-30
2.3.1 Start ............................................................................................................................. 2-30
2.3.1.1 Boarding the machine safely ............................................................................ 2-30
2.3.1.2 Seat adjustment ................................................................................................. 2-31
2.3.1.3 Fastening seat belt............................................................................................. 2-31
2.3.1.4 Inspection before engine start.......................................................................... 2-32
2.3.1.5 Starting the machine safely .............................................................................. 2-32
2.3.1.6 Engine start in cold weather ............................................................................. 2-33
2.3.1.7 Required auxiliary equipment for start ............................................................ 2-33
2.3.1.8 After starting the engine .................................................................................... 2-34
2.3.2 Operation .................................................................................................................... 2-34
2.3.2.1 Inspection before operation .............................................................................. 2-34
2.3.2.2 Precautions before operation ........................................................................... 2-35
2.3.2.3 Verifying the travel direction ............................................................................. 2-35
2.3.2.4 Safety rules for changing the machine direction ........................................... 2-36
2.3.2.5 Travel safety rules.............................................................................................. 2-38
2.3.2.6 Driving the machine safely................................................................................ 2-39
2.3.2.7 Operation on slope............................................................................................. 2-40
2.3.2.8 Operation in snowy weather ............................................................................. 2-41
2.3.2.9 Forbidden operation........................................................................................... 2-41
II Operation and Maintenance Manual-12-2015

2.3.3 Parking ........................................................................................................................ 2-44

2.3.3.1 Choosing parking lot .......................................................................................... 2-44
2.3.3.2 Machine shutdown ............................................................................................. 2-45
2.3.4 Transportation............................................................................................................ 2-45
2.3.4.1 Transportation..................................................................................................... 2-45
2.3.4.2 Loading and unloading ...................................................................................... 2-46
2.3.5 Battery......................................................................................................................... 2-47
2.3.6 Towing ......................................................................................................................... 2-49
2.3.7 Lifting by excavator ................................................................................................... 2-50
2.4 Safe maintenance instruction........................................................................................... 2-51
2.4.1 Precautions before maintenance ............................................................................ 2-51
2.4.2 Self-preparation ......................................................................................................... 2-51
2.4.3 Preparation of working area..................................................................................... 2-52
2.4.4 Steps of engine shutdown before maintenance.................................................... 2-53
2.4.5 Warning decal ............................................................................................................ 2-54
2.4.6 Proper tools ................................................................................................................ 2-54
2.4.7 Maintenance during engine running ....................................................................... 2-55
2.4.8 Operation under the machine .................................................................................. 2-56
2.4.9 Track maintenance.................................................................................................... 2-56
2.4.10 Safety precautions for track tension adjustment................................................. 2-57
2.4.11 Don’t remove the buffer spring .............................................................................. 2-57
2.4.12 Be careful of hot cooling system ........................................................................... 2-58
2.4.13 Safe operation of high pressure hose .................................................................. 2-58
2.4.14 Be careful of high pressure liquid.......................................................................... 2-59
2.4.15 Welding operation ................................................................................................... 2-60
2.4.16 Safe maintenance of HVAC group........................................................................ 2-60
2.4.17 Precautions related to high voltage ...................................................................... 2-61
2.4.18 Accumulator ............................................................................................................. 2-61
2.4.19 Preventing the danger of fire and explosion........................................................ 2-62
2.4.20 Regular replacement of safety related parts ....................................................... 2-62
2.4.21 Maintenance operation........................................................................................... 2-62
2.4.22 Proper waste treatment .......................................................................................... 2-63
3 Technical Specifications.............................................................................................3-1
3.1 Overall dimensions ...............................................................................................................3-3
3.2 Working range .......................................................................................................................3-4
3.3 Technical parameters ...........................................................................................................3-5
4 Operation.............................................................................................................................4-1
4.1 General drawing of machine................................................................................................4-5
Operation and Maintenance Manual-12-2015 III

4.2 Description of controls and instruments.............................................................................4-6

4.2.1 Display ...........................................................................................................................4-6
4.2.2 Switch.......................................................................................................................... 4-18
4.2.2.1 General ................................................................................................................ 4-18
4.2.2.2 Ignition switch ..................................................................................................... 4-18
4.2.2.3 Throttle control knob .......................................................................................... 4-20
4.2.2.4 Working lamp switch.......................................................................................... 4-20
4.2.2.5 Ceiling lamp switch ............................................................................................ 4-21
4.2.2.6 Wiper switch........................................................................................................ 4-22
4.2.2.7 Washer switch .................................................................................................... 4-22
4.2.2.8 Horn switch ......................................................................................................... 4-23
4.2.2.9 Indoor lamp switch ............................................................................................. 4-23
4.2.2.10 Cigar lighter and auxiliary power supply....................................................... 4-24
4.2.2.11 Fault indicator lamp.......................................................................................... 4-24
4.2.2.12 Charging indicator lamp .................................................................................. 4-24
4.2.2.13 Refueling pump switch .................................................................................... 4-25
4.2.2.14 Alarm lamp (optional) ...................................................................................... 4-25
4.2.2.15 Camera (optional) ............................................................................................ 4-26
4.2.2.16 Emergency stop switch ................................................................................... 4-26
4.2.3 Control lever and pedal............................................................................................. 4-27
4.2.3.1 General ................................................................................................................ 4-27
4.2.3.2 Safety lock control lever .................................................................................... 4-28
4.2.3.3 Traveling control mechanism ........................................................................... 4-29
4.2.3.4 Control levers...................................................................................................... 4-30
4.2.4 Roof ............................................................................................................................. 4-31
4.2.5 Windshield .................................................................................................................. 4-32
4.2.6 Doors and windows of cab ....................................................................................... 4-39
4.2.7 Cup holder .................................................................................................................. 4-40
4.2.8 Ashtray ........................................................................................................................ 4-40
4.2.9 Information pack ........................................................................................................ 4-41
4.2.10 Drink box................................................................................................................... 4-41
4.2.11 Emergency exit ........................................................................................................ 4-42
4.2.12 Fire Extinguisher ..................................................................................................... 4-43
4.2.13 Controller .................................................................................................................. 4-43
4.2.14 Fuse link ................................................................................................................... 4-44
4.2.15 Integrated fuse box ................................................................................................. 4-45
4.2.16 HVAC group ............................................................................................................. 4-46
4.2.16.1 Control panel .................................................................................................... 4-46
4.2.16.2 Control switch and LCD .................................................................................. 4-47
IV Operation and Maintenance Manual-12-2015

4.2.16.3 Operation of HVAC .......................................................................................... 4-52

4.2.16.4 Use HVAC carefully ......................................................................................... 4-55
4.2.17 Radio......................................................................................................................... 4-57
4.2.17.1 Control panel .................................................................................................... 4-57
4.2.17.2 Control key and LCD ....................................................................................... 4-57
4.2.17.3 Radio operation................................................................................................ 4-59
4.2.18 Door lock................................................................................................................... 4-62
4.2.19 Lock cap ................................................................................................................... 4-62
4.2.19.1 General.............................................................................................................. 4-62
4.2.19.2 Open and close the lock cap .......................................................................... 4-63
4.2.19.3 Open and close the lock cover....................................................................... 4-64
4.2.20 Tool box..................................................................................................................... 4-65
4.2.21 Lubricating grease pump rack (if assembled) ..................................................... 4-65
4.3 Operation and control of machine.................................................................................... 4-65
4.3.1 Before engine start .................................................................................................... 4-65
4.3.1.1 Routing inspection ............................................................................................. 4-65
4.3.1.2 Inspection before start....................................................................................... 4-67
4.3.1.3 Adjustment before operation ............................................................................ 4-74
4.3.1.4 Operation before engine start........................................................................... 4-78
4.3.2 Engine start ................................................................................................................ 4-80
4.3.3 Engine preheating ..................................................................................................... 4-82
4.3.4 Warm-up operation.................................................................................................... 4-83
4.3.5 Stop the engine.......................................................................................................... 4-84
4.3.6 Machine operation..................................................................................................... 4-84
4.3.6.1 General ................................................................................................................ 4-84
4.3.6.2 Preparation of moving machine ....................................................................... 4-85
4.3.6.3 Move machine .................................................................................................... 4-86
4.3.6.4 Stop machine...................................................................................................... 4-87
4.3.7 Machine steering ....................................................................................................... 4-88
4.3.7.1 General ................................................................................................................ 4-88
4.3.7.2 Turn the machine when it stops ....................................................................... 4-88
4.3.7.3 In-situ steering .................................................................................................... 4-90
4.3.8 Control and operation of work equipment.............................................................. 4-90
4.3.9 Prohibited operation.................................................................................................. 4-92
4.3.10 Allowed water depth................................................................................................ 4-96
4.3.11 Operation on the slope ........................................................................................... 4-96
4.3.11.1 General .............................................................................................................. 4-96
4.3.11.2 Downhill traveling ............................................................................................. 4-98
4.3.11.3 Engine flameout on the slope......................................................................... 4-98
Operation and Maintenance Manual-12-2015 V

4.3.11.4 Cab door on the slope ..................................................................................... 4-98

4.3.12 Drive the machine out of the mud ......................................................................... 4-99
4.3.12.1 General.............................................................................................................. 4-99
4.3.12.2 Track on one side gets stuck in the mud ...................................................... 4-99
4.3.12.3 Tracks on both sides get stuck in the mud ................................................... 4-99
4.3.13 Recommended purpose....................................................................................... 4-100
4.3.13.1 General............................................................................................................ 4-100
4.3.13.2 Backhoe operation......................................................................................... 4-100
4.3.13.3 Ditching work .................................................................................................. 4-101
4.3.13.4 Loading operation .......................................................................................... 4-101
4.3.14 Parking.................................................................................................................... 4-102
4.3.15 Machine inspection after daily work.................................................................... 4-104
4.3.16 Locking.................................................................................................................... 4-105
4.3.17 Operation in cold season ..................................................................................... 4-105
4.3.17.1 Description of operation in cold weather .................................................... 4-105
4.3.17.2 After daily work............................................................................................... 4-106
4.3.17.3 After the cold season..................................................................................... 4-107
4.3.18 Long-term storage................................................................................................. 4-108
4.3.18.1 Before storage................................................................................................ 4-108
4.3.18.2 During storage................................................................................................ 4-108
4.3.18.3 After storage ................................................................................................... 4-109
4.3.18.4 Start the engine after long-term storage..................................................... 4-109
4.4 Transportation....................................................................................................................4-110
4.4.1 General ......................................................................................................................4-110
4.4.2 Transportation method.............................................................................................4-110
4.4.3 Machine loading and unloading machine with trailer ..........................................4-111
4.4.3.1 General ...............................................................................................................4-111
4.4.3.2 Loading ...............................................................................................................4-112
4.4.3.3 Secure the machine..........................................................................................4-114
4.4.3.4 Unloading ...........................................................................................................4-117
4.5 Lifting...................................................................................................................................4-119
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Guideline ........................................................................................................5-5
5.2 Treatment of Oil, Fuel and Coolant.....................................................................................5-7
5.2.1 Oil....................................................................................................................................5-7
5.2.2 Fuel.................................................................................................................................5-8
5.2.3 Coolant in the cooling system.....................................................................................5-9
5.2.4 Grease ...........................................................................................................................5-9
5.2.5 Storage of engine oil and fuel .................................................................................. 5-10
VI Operation and Maintenance Manual-12-2015
5.2.6 Filter element ............................................................................................................. 5-10

5.3 Electrical System Maintenance........................................................................................ 5-10
5.4 Wear Parts ...........................................................................................................................5-11
5.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 5-13
5.6 Tightening Torque .............................................................................................................. 5-16
5.7 Safety Critical Parts ........................................................................................................... 5-17
5.8 Maintenance Schedule...................................................................................................... 5-18
5.9 Maintenance Procedures.................................................................................................. 5-21
5.9.1 Initial 50-hour maintenance (after the first 50 hours only) ................................... 5-21
5.9.2 Maintenance as demanded...................................................................................... 5-22
5.9.2.1 Checking and tightening track shoe bolts....................................................... 5-22
5.9.2.2 Checking and adjusting track tension ............................................................. 5-23
5.9.2.3 Replacement of bucket...................................................................................... 5-26
5.9.2.4 Replacing bucket teeth (horizontal pin type).................................................. 5-28
5.9.2.5 Adjusting bucket clearance............................................................................... 5-30
5.9.2.6 Checking window washer fluid level and filling washer fluid........................ 5-31
5.9.2.7 Checking and maintaining air conditioning..................................................... 5-32
5.9.2.8 Checking air springs .......................................................................................... 5-34
5.9.3 Checks before startup............................................................................................... 5-36
5.9.4 Maintenance after every 100 h ................................................................................ 5-36
5.9.4.1 Lubricating work equipment.............................................................................. 5-36
5.9.5.1 Checking, cleaning and replacing air filter element ...................................... 5-39
5.9.5.2 Maintenance instructions of oil bath type air filter ......................................... 5-42
5.9.5.3 Checking and adjusting belt tension of HVAC compressor ......................... 5-45
5.9.5.4 Lubricating swing bearing ................................................................................. 5-46
5.9.5.5 Checking whether pipe clamps and collars of the hydraulic system are
abnormal ............................................................................................................ 5-46
5.9.6.1 General ................................................................................................................ 5-47
5.9.6.2 Checking the level of grease in swing pinion and add grease..................... 5-47
5.9.6.3 Replacing the oil in engine oil pan, and replace the oil filter
element............................................................................................................... 5-48
5.9.6.4 Replacing fuel primary filter element............................................................... 5-50
5.9.6.5 Replacing fuel secondary filter and fine filter element .................................. 5-52
5.9.6.6 Cleaning and inspecting radiator and cooler fins .......................................... 5-55
5.9.6.7 Cleaning the ventilation/circulation filter of HVAC ......................................... 5-56
5.9.6.8 Checking the oil level in swing gearbox and refilling..................................... 5-59
5.9.6.9 Checking the oil level of travel gearbox and refilling..................................... 5-60
Operation and Maintenance Manual-12-2015 VII

5.9.6.10 Replacing hydraulic tank breather filter element ......................................... 5-61

5.9.7 Maintenance after every 1000 h.............................................................................. 5-62
5.9.7.1 General ................................................................................................................ 5-62
5.9.7.2 Replacing hydraulic oil filter element............................................................... 5-62
5.9.7.3 Replacing the oil in swing gearbox .................................................................. 5-64
5.9.7.4 Checking the cab door lock and the front window lock for
fastening............................................................................................................. 5-66
5.9.7.5 Checking the lubricating oil of cab door hinge and front window slide
guide and refill ................................................................................................... 5-67
5.9.7.6 Checking the rocker nut of wiper for looseness............................................. 5-68
5.9.7.7 Checking all fastening parts of the engine exhaust pipe clamp .................. 5-68
5.9.7.8 Checking the fan belt tension and replace the fan belt................................. 5-68
5.9.7.9 Checking the nitrogen pressure in accumulator (for hammer) .................... 5-68
5.9.7.10 Adding grease into swing reducer ................................................................. 5-68
5.9.8.1 General ................................................................................................................ 5-69
5.9.8.2 Replacing the oil in final drive case ................................................................. 5-69
5.9.8.3 Cleaning hydraulic tank strainer....................................................................... 5-70
5.9.8.4 Checking the nitrogen pressure in accumulator ............................................ 5-71
5.9.8.5 Replacing the oil in hydraulic tank ................................................................... 5-74
5.9.8.6 Replacing the engine coolant and cleaning the inside of cooling
system ................................................................................................................ 5-76
5.9.8.7 Checking alternator............................................................................................ 5-78
5.9.8.8 Checking and adjusting engine valve clearance ........................................... 5-78
5.9.9.1 General ................................................................................................................ 5-78
5.9.9.2 Checking water pump........................................................................................ 5-78
5.9.9.3 Checking starter motor ...................................................................................... 5-78
5.9.9.4 Replacing accumulator...................................................................................... 5-79
5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber for
hardening ........................................................................................................... 5-80
5.9.9.6 Checking the operation of compressor ........................................................... 5-80
5.9.10 Maintenance after every 8000 h............................................................................ 5-80
5.9.10.1 General.............................................................................................................. 5-80
5.9.10.2 Replacing high pressure pipe clamp............................................................. 5-81
5.9.11 Maintenance after every 10000 h.......................................................................... 5-81
6 Troubleshooting ..............................................................................................................6-1
6.1 Special Instructions...............................................................................................................6-3
VIII Operation and Maintenance Manual-12-2015

6.2 Preparations before Troubleshooting.................................................................................6-4

6.2.1 Inspections before Troubleshooting ..........................................................................6-4
6.2.2 Precautions during Troubleshooting..........................................................................6-5
6.2.3 Precautions in Circuit Troubleshooting .....................................................................6-7
6.2.4 Precautions for Handling Hydraulic Components....................................................6-7
6.2.5 Towing ......................................................................................................................... 6-10
6.3 Engine Faults.......................................................................................................................6-11
6.3.1 Faults Diagnosis Table for Engine ...........................................................................6-11
6.3.2 High Water Temperature .......................................................................................... 6-16
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure)............................. 6-17
6.3.4 Fuel Run-Out.............................................................................................................. 6-18
6.3.5 Engine Kick-Back ...................................................................................................... 6-19
6.4 Electrical System Failure .................................................................................................. 6-19
6.4.1 Faults Diagnosis Table of Electrical System.......................................................... 6-19
6.4.2 Display Monitor .......................................................................................................... 6-23
6.4.3 Battery......................................................................................................................... 6-25
6.4.3.1 General ................................................................................................................ 6-25
6.4.3.2 Removal and Refitting of Battery ..................................................................... 6-26
6.4.3.3 Battery Charge ................................................................................................... 6-27
6.4.3.4 Start Engine with Auxiliary Wire....................................................................... 6-27
6.5 Hydraulic System Failure .................................................................................................. 6-30
6.6 Other Common Faults ....................................................................................................... 6-34
7 Accessories and Options ...........................................................................................7-1

7.1 Safety precautions ................................................................................................................7-3
7.2 Hydraulic control component and line supporting accessories ......................................7-5
7.2.1 Position of components ...............................................................................................7-5
7.2.2 Hydraulic lines...............................................................................................................7-6
7.2.3 Removal and installation of accessories...................................................................7-9
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter....................................... 7-13
7.2.5 Long-term storage ..................................................................................................... 7-14
7.3 Recommended accessory operation .............................................................................. 7-14
7.3.1 General ....................................................................................................................... 7-14
7.3.2 Hydraulic breaker ...................................................................................................... 7-15
7.3.3 Operation of hydraulic breaker ................................................................................ 7-15
7.3.4 Forbidden operation.................................................................................................. 7-17
7.3.5 Greasing of hydraulic breaker ................................................................................. 7-19
7.4 Quick coupler and control system.................................................................................... 7-20
7.4.1 Operation method of quick coupler......................................................................... 7-20
7.4.2 Precautions for safety operation of quick coupler................................................. 7-22
Operation and Maintenance Manual-12-2015 IX

7.5 Refueling system................................................................................................................ 7-23

7.5.1 Introduction to refueling system .............................................................................. 7-23
7.5.2 Composition of refueling system ............................................................................. 7-24
X Operation and Maintenance Manual-12-2015

SY500H Hydraulic Excavator Foreword
Foreword
1 Foreword..............................................................................................................................1-1
1.1 General ...................................................................................................................................1-3
1.2 Safety information .................................................................................................................1-4
1.3 Page description....................................................................................................................1-6
1.4 Introduction ............................................................................................................................1-6
1.4.1 General .........................................................................................................................1-6
1.4.2 Directions of the machine ..........................................................................................1-7
1.4.3 Running-in of new machines .....................................................................................1-7
1.5 Product information...............................................................................................................1-8
1.5.1 General .........................................................................................................................1-8
1.5.2 Machine data plate......................................................................................................1-8
1.5.3 Engine data plate ........................................................................................................1-8
Operation and Maintenance Manual-12-2015 1-1

Foreword SY500H Hydraulic Excavator
WARNING
Read and understand all safety precautions and instructions in this manual before reading any
other manuals provided with this machine and before operation or maintaining it.Failure to do
this could result in death or serious injury.
1-2 Operation and Maintenance Manual-12-2015

1.Foreword
1.1 General
This manual is a guide for correct use of the machine and mainly provides technical and safety in-
formation required in operation. Please be sure to read each part of it carefully.
Only qualified and experienced operators with an official license (according to local laws) can oper-
ate the machine.
Make sure that the relevant laws and regulations of the state, a province, an autonomous region or
a municipality are always observed in operation of the machine, and the operation safety informa-
tion and instructions contained herein are only provided as suggestions and cautions.
We cannot foresee all situations in operation and maintenance that may pose risks. Therefore, the
safety information in this manual and on the machine do not contain all the possible safety meas-
ures. When methods or actions other than those specifically recommended or allowed in this man-
ual are used or taken, you are obliged to take necessary measures to ensure safety.
Unauthorized retrofitting or abuse of the machine may influence the performance or even cause
greater safety hazard, for instance, settings more than the specified fuel quantity may overload the
machine. Please drive and use the machine carefully, as faulty operation and misuse may also
cause damage, and we do not accept any responsibility for the loss thus caused.
The machine referred to in this manual is used for various operations under normal conditions;
please do not use it in an inflammable and explosive place or an area with asbestic dust.
This machine is subject to the electromagnetism and capacitance test according to EN13309-
2000. Therefore, all the unapproved electronic auxiliary devices such as communication apparatus
shall be tested before installation and use to ensure that they will not produce electromagnetic in-
terference to the machine.
All data, charts and specifications in this manual are the latest product information available at the
time of publication. We reserve the right to alter the above information without notice. Please con-
tact us or our authorized dealer for the latest product information or the problems related to the in-
formation covered in this manual.
Scope of application of machine of normal series: altitude below 2000 m, atmospheric tempera-
ture: -20°C ~ 40°C.

CAUTION
Before operation and maintenance, the operators and maintenance personnel must do the
following:
• Be sure to read through and understand this manual.
• Read and fully understand the safety notices in the manual and safety labels on the machine.
• Shall in no circumstances use the machine for applications or operations forbidden in the
manual.
• If fuel amount, particulate size or latitude exceeds the upper limit specified for the model and
application, it may result in injuries and is not covered by the warranty.
• Always keep the manual in the cab for reference at anytime.
• Immediately contact our authorized dealer for reissue or replacement if this manual is lost or
stained and thus unreadable.
• This manual shall be deemed as a permanent part of the machine, so please be sure to hand it
over to a new user together with the machine if you resell it.
• Hydraulic excavators that provided by Sany Heavy Machinery Co., Ltd. to the country of pur-
chase meet all applicable regulations and standards. Purchasing from another country or a per-
son of another country may deprive you of some safety devices and specifications necessary
for use in your country. If you have any questions about hydraulic excavator’s compliance with
national standards and regulations for use, contact your Sany Heavy Machinery Co., Ltd. au-
thorized distributor before using it.
1.2 Safety information

For safe use of the machine, this manual contains and explains the safety precautions and labels
attached to the machine, to provide a description of potential hazards involved and methods to
avoid them.
Before operation and maintenance, users and after-sales service personnel must get familiar with
the warning signs and symbols on the machine, strictly observe the safety rules and recommenda-
tions in this manual, and actively take safety precautions and countermeasures to minimize the
risks of personal injuries, machine damage due to improper repair or the risks due to unsafe
factors.
1. Safety warning
A safety warning comprises an attention symbol and signal words, used as a reminder of potential
hazards that may cause personal injuries or damage. Safety warnings can be classified by signal
words according to the severity of hazardous situations.
Three types of signal words are used in this manual: DANGER, WARNING and CAUTION, each
representing the following:

Existing dangers that, if not evaded, will cause deaths or severe injuries.
Potential dangers that, if not evaded, may cause deaths or severe injuries.
Potential dangers that, if not evaded, may cause light or moderate injuries. The word
“caution” can also be used in some occasions as a reminder of unsafe operations that
may cause personal injuries, damage to the machine and environment.
Examples of safety warnings
WARNING
• Before standing up from the driver seat, make sure to set the control lever to the LOCK
position.
• Severe injuries or deaths can occur if the control lever is not locked and touched by accident.
2. Safety decals
A safety decals is attached to the machine to remind the operators or maintenance personnel of
potential hazards during operation or maintenance.
The “literal safety decals” and “graphic safety decals” are used on the machine to represent safety
measures.
a. Examples of literal safety decals
To release pressure, loosen

only one turn. If the valve is
loosened too much, grease
under high pressure may
squirt out.
A820601990968
Fig.1-1

b. Examples of graphic safety decals
Safety icons are graphic representations of

the severity of hazards, equivalent to the liter-
al statement. Graphics are used in these
safety icons to keep operators or maintenance
personnel informed of the type and severity of
hazards.
In the figure on the right, the safety icon above

represents the type of hazard and the icon be-
low indicates the method to avoid it.
A820601990973
Fig.1-2
1.3 Page description

For the purpose of this manual, the page is numbed by chapter. Example: 3-20
Example: 3-20
Page 20 in Chapter 3
Chapter 3
1.4 Introduction
1.4.1 General
Sany hydraulic excavator is designed for:
Excavation
Leveling
Ditching
Loading
Demolition
Please refer to the relevant part of this manual in detail.
Numbers in illustrations are corresponding to those in 【】in the text. (Example: 1→【1】)
The international system of units (SI) is used in this manual.

1.4.2 Directions of the machine
In this manual, the front, back, left and right

are directions of travel when seen from the
A
cab with the cab facing forward and the driv-
ing wheel behind the machine.
【A】Front
E
【B】Back
【C】Left C D
【D】Right
【E】Driver seat
F
【F】Driving wheel
B
CZ335-1101001
Fig.1-3
1.4.3 Running-in of new machines
Our machines are fully commissioned and

tested before delivery. However, keeping ma-
chines at full load before running-in process
will seriously affect the performance and
shorten the useful life.
Be sure to carry out running-in within the initial

100 h (according to the indication of working
hours on the display).
Be sure that you are fully aware of the content

of this manual and note the following during
the running-in process:
After start-up, keeping the machine idling for 3

~ 5 min. During this time, do not operate the
control lever or fuel control knob, and then
slowly set the engine to 1500 rpm until the
coolant temperature reaches about 60°C.
Avoid high-speed operation at heavy load.

1.5 Product information

1.5.1 General
To maintain, order or replace components, please inform our authorized dealer of the following:
1.5.2 Machine data plate
The machine data plate is at lower right of the cab (as shown below).
Hydraulic Excavator
MODEL
NUMBER
WEIGHT
RATED POWER
SANY HEAVY MACHINERY LIMITED.
CQ13031501-2
Fig.1-4
1.5.3 Engine data plate
The engine data plate is located as shown below. The location of the engine data plate may vary
with the engine type.

Type approval according to the Emission

Standard for the Diesel Engines of Non-road
Mobile Machinery (China III)
Engine model ： 6WG1XKSC-01
Engine power ： 300kW/ 1800r/min
Manufacturer ： Isuzu Motors Limited
Production date ：
Power range ：280≤ kW ≤ 377
Engine number ：
14111901
Fig.1-5


SY500H Hydraulic Excavator Safety
Safety
2 Safety.....................................................................................................................................2-1
2.1 Safety decals .........................................................................................................................2-5
2.1.1 General .........................................................................................................................2-5
2.1.2 Location ........................................................................................................................2-6
2.1.3 Description ...................................................................................................................2-7
2.2 Safety information .............................................................................................................. 2-13
2.2.1 Safety rules ............................................................................................................... 2-13
2.2.2 Handling of abnormalities ....................................................................................... 2-13
2.2.3 Personal protective equipment .............................................................................. 2-14
2.2.4 Fire extinguisher and first-aid kit ............................................................................ 2-15
2.2.5 Safety equipment ..................................................................................................... 2-15
2.2.6 Keeping the machine clean .................................................................................... 2-16
2.2.7 Keeping the cab clean ............................................................................................. 2-16
2.2.8 Locking of safety lock control lever........................................................................ 2-17
2.2.9 Armrest and ladder .................................................................................................. 2-17
2.2.10 Precautions for working at heights ...................................................................... 2-18
2.2.11 Keeping clear of the accessory ............................................................................ 2-18
2.2.12 Don’t get stuck in the articulation section ........................................................... 2-18
2.2.13 Preventing scald..................................................................................................... 2-19
2.2.13.1 Hot coolant....................................................................................................... 2-19
2.2.13.2 Hot oil ............................................................................................................... 2-20
2.2.14 Fire and explosion prevention.............................................................................. 2-21
2.2.14.1 Fire caused by fuel or engine oil................................................................... 2-21
2.2.14.2 Fire caused by inflammable materials......................................................... 2-22
2.2.14.3 Fire caused by electrical wire........................................................................ 2-22
2.2.14.4 Fire caused by hydraulic circuit .................................................................... 2-22
2.2.14.5 Fire caused by lighting equipment ............................................................... 2-22
2.2.14.6 Fire caused by heat shield ............................................................................ 2-22
2.2.15 Actions in case of a fire ......................................................................................... 2-22
Safety SY500H Hydraulic Excavator
2.2.16 Windshield cleaning solution................................................................................ 2-23

2.2.17 Preventing flying components.............................................................................. 2-23
2.2.18 Prevent falling, flying and invading objects ........................................................ 2-23
2.2.19 Accessory installation............................................................................................ 2-24
2.2.20 Accessory combination ......................................................................................... 2-24
2.2.21 Cab window glass .................................................................................................. 2-24
2.2.22 Unauthorized retrofit.............................................................................................. 2-24
2.2.23 Site survey in advance .......................................................................................... 2-25
2.2.24 Operation on loose ground ................................................................................... 2-26
2.2.25 Don’t approach high voltage cable ...................................................................... 2-27
2.2.26 Ensuring favorable view........................................................................................ 2-28
2.2.27 Ventilation of working environment ..................................................................... 2-29
2.2.28 Prevention of asbestos dust ................................................................................. 2-29
2.2.29 Cab emergency exit............................................................................................... 2-30
2.3 Safe machine operation .................................................................................................... 2-30
2.3.1 Start............................................................................................................................ 2-30
2.3.1.1 Boarding the machine safely........................................................................... 2-30
2.3.1.2 Seat adjustment ................................................................................................ 2-31
2.3.1.3 Fastening seat belt ........................................................................................... 2-31
2.3.1.4 Inspection before engine start......................................................................... 2-32
2.3.1.5 Starting the machine safely ............................................................................. 2-32
2.3.1.6 Engine start in cold weather ............................................................................ 2-33
2.3.1.7 Required auxiliary equipment for start........................................................... 2-33
2.3.1.8 After starting the engine................................................................................... 2-34
2.3.2 Operation................................................................................................................... 2-34
2.3.2.1 Inspection before operation............................................................................. 2-34
2.3.2.2 Precautions before operation.......................................................................... 2-35
2.3.2.3 Verifying the travel direction ............................................................................ 2-35
2.3.2.4 Safety rules for changing the machine direction .......................................... 2-36
2.3.2.5 Travel safety rules............................................................................................. 2-38
2.3.2.6 Driving the machine safely .............................................................................. 2-39
2.3.2.7 Operation on slope ........................................................................................... 2-40
2.3.2.8 Operation in snowy weather............................................................................ 2-41
2.3.2.9 Forbidden operation ......................................................................................... 2-41
2.3.3 Parking....................................................................................................................... 2-44
2.3.3.1 Choosing parking lot......................................................................................... 2-44
2.3.3.2 Machine shutdown............................................................................................ 2-45
2.3.4 Transportation........................................................................................................... 2-45
2.3.4.1 Transportation ................................................................................................... 2-45
2.3.4.2 Loading and unloading..................................................................................... 2-46
2.3.5 Battery........................................................................................................................ 2-47
2.3.6 Towing........................................................................................................................ 2-49

2.3.7 Lifting by excavator .................................................................................................. 2-50
2.4 Safe maintenance instruction........................................................................................... 2-51
2.4.1 Precautions before maintenance........................................................................... 2-51
2.4.2 Self-preparation........................................................................................................ 2-51
2.4.3 Preparation of working area ................................................................................... 2-52
2.4.4 Steps of engine shutdown before maintenance .................................................. 2-53
2.4.5 Warning decal........................................................................................................... 2-54
2.4.6 Proper tools............................................................................................................... 2-54
2.4.7 Maintenance during engine running...................................................................... 2-55
2.4.8 Operation under the machine................................................................................. 2-56
2.4.9 Track maintenance .................................................................................................. 2-56
2.4.10 Safety precautions for track tension adjustment ............................................... 2-57
2.4.11 Don’t remove the buffer spring ............................................................................. 2-57
2.4.12 Be careful of hot cooling system.......................................................................... 2-58
2.4.13 Safe operation of high pressure hose ................................................................. 2-58
2.4.14 Be careful of high pressure liquid ........................................................................ 2-59
2.4.15 Welding operation.................................................................................................. 2-60
2.4.16 Safe maintenance of HVAC group ...................................................................... 2-60
2.4.17 Precautions related to high voltage..................................................................... 2-61
2.4.18 Accumulator............................................................................................................ 2-61
2.4.19 Preventing the danger of fire and explosion ...................................................... 2-62
2.4.20 Regular replacement of safety related parts...................................................... 2-62
2.4.21 Maintenance operation ......................................................................................... 2-62
2.4.22 Proper waste treatment......................................................................................... 2-63

WARNING

2.Safety
2.1 Safety decals

2.1.1 General
This machine uses the following warning and safety decals.

• Make sure to know clearly the location and content of the decals.
• Please keep the decals in the right positions and clean to ensure their readability. Do not clean
the decals with organic solvent or gasoline, which may peel off the decal paint.
• Treat other decals in the same way as warning and safety decals.
• When the decals are damaged, lost or unreadable, please replace them. As for detail of decal
part number, please see this manual or the actual decals.

2.1.2 Location
16 14
17
12
3 A
B 5
1 4
9
18 10
7 15
B
13
11
12
CZ425-1102001
Fig.2-1

2.1.3 Description
[1] Read manual" warning decal
• Please read this manual before operation,

maintenance, disassembly, assembly and
transportation of the machine.
A820601990971
Fig.2-2
[2] Front window lockout warning decal
• This decal indicates the danger of the front

window falling down.
• After raising the front window, please lock it
with the lock pin.
A820699001019
Fig.2-3
[3] Operation instruction decal
• To avoid casualty during operation, please

verify the running status of the machine and
the displayed running mode, pay attention
to the surrounding environment and operate
the machine slowly.
A820601990961
Fig.2-4

[4] High voltage warning decal
• This decal indicates if the machine is too

close to the power transmission line, there
will be the danger of electric shock.
• Keep the safety distance from the power
transmission line.
A820601990974
Fig.2-5
[5] Power-off warning decal
• Before leaving the machine, please lower

down the work equipment to the ground,
pull the safety control lever to the lock posi-
tion and pull out the ignition key.
A820699001020
Fig.2-6
[6] Emergency exit decal
A820601990969
Fig.2-7

[7] "No entry" warning decal
• The decal indicates there is the danger of

being collided by the machine, please don’t
enter the turning circle of the machine.
• Keep away from the machine when it is
operating.
A820699001016
Fig.2-8
[8] Work equipment caution decal
• The decal indicates there is the danger of

being collided by the work equipment.
• Keep away from the machine when it is
operating.
A820601990963
Fig.2-9
[9] Hot surface warning decal
• Please don’t touch the hot surface to avoid

DANGER
scald.
10123433
Fig.2-10

[10] Anti-spray warning decal
• Please release the tank pressure in accord-

ance with the operation instruction before
opening the tank cover like fuel tank cover,
and open the cover slowly to avoid
spraying.
A820699000948
Fig.2-11
[11] "Injury by fan” warning decal
• Please keep away from the rotary object to DANGER

avoid injury.
A820600000002
Fig.2-12
[12] Track tension adjustment warning decal
• Don’t loosen the track more than 1 turn, or

there will be the danger of injury caused by
the flying regulating valve under high
pressure.
To release pressure, loosen
only one turn. If the valve is
loosened too much, grease
under high pressure may
squirt out.
A820601990968
Fig.2-13

[13] Belt safety warning decal
• This decal indicates the danger of the rotary

belt.
• Please stop the belt before maintenance.
STOP
A820699001017
Fig.2-14
[14] Fall warning decal
• There may be the danger of falling.

• Don’t stay close to the edge of the machine.
A820601990926
Fig.2-15

[15] "Stand clear of the area" warning decal
• Stand clear of the area as there may be the

danger of falling.
A820601990973
Fig.2-16
[16] No-sitting warning decal
A820699001023
Fig.2-17
[17] Water separator drain decal
注意 CAUTION
为放水方向；
This is the direction to release the water.
为拧紧方向。
This is the direction to close the drain.
适当拧紧,不得用力过大,否则将引起油水分离器
损坏。
Tighten with proper force to prevent damage
to the water separator.
A820601990962
Fig.2-18

[18] Refrigerant change instruction decal
更换系统部件时,必须补充冷冻油.
Refrigerant must be refilled when
replacing air-conditioning system
components.
A820699001284
Fig.2-19
2.2 Safety information

2.2.1 Safety rules
• Only trained workers can be assigned to

operate and maintain the machine.
• Please abide by all safety rules, precautions
and instructions when operating and main-
taining the machine.
• Alcohol and medicine will severely reduce/
weaken workers’ ability to operate or main-
tain the machine in a safe manner, endan-
gering himself/herself and other people on
the site.
• When working with another operator or a
commander, please keep all informed of all
adopted hand signals.
2.2.2 Handling of abnormalities
When any abnormalities (noise, vibration,

odor, incorrect instrument display, smoke, oil
leakage and etc. or any abnormal display in
the warning device or monitor) are discovered
in the process of operation and maintenance,
please report to the supervisor and take nec-
essary measures. Don’t operate the machine
before removing all faults.

2.2.3 Personal protective equipment
Wear tights or work clothes and protective

equipment required by working conditions.
You may need:
• Helmet
• Safety shoes
• Safety glasses, goggles or face shield
• Protective gloves
• Earplug
• Reflective protective clothing
• Anti-dust mask CZ335-1102002
Wear necessary safety protection equipment Fig.2-20

and the equipment required by the employer,
the public service management department,
and the government, as well as laws and reg-
ulations. Don't take chances to avoid un-
necessary danger.
CAUTION
• Don’t wear accessories and loose clothes.
There will be the danger of hooking the
control lever or other protruding
components.
• If the hair is too long and exposed out of
the helmet, there will be the danger of in-
tertwining in the machine.
• Wear the helmet and safety shoes all the
time. If necessary, please wear safety
glasses, mask, gloves, earplug and safety
belt when operating or maintain the
machine.
• Please check that all protective equipment
function normally before use.

2.2.4 Fire extinguisher and first-aid kit
To prevent injury or fire, please observe the

following precautions:
• Prepare first-aid kit and fire extinguisher
nearby.
• Please read the instruction attached on the
fire extinguisher carefully to ensure proper
use of the fire extinguisher.
• Please check and maintain the fire extin-
guisher regularly to ensure it’s available at
CZ335-1102003
any time.
• Please check the first-aid kit regularly and Fig.2-21
add medicine if necessary.
• Establish emergency plan to deal with fire
and accident.
2.2.5 Safety equipment
To protect you and the people around, your

machine can be equipped with the following
safety equipment. Please ensure each one is
fixed in the right position and in the working
condition.
• Falling object protective structures
• Protective guard
• Guard board
• Lamps
• Safety decals CZ335-1102004
• Horn Fig.2-22
• Travel warning
• Mirror
• Fire extinguisher
• First-aid kit
• Wiper blade
Please ensure all equipment above is avail-

able. You are forbidden to take down or dis-
connect any safety equipment.

CAUTION
• Ensure all protective covers and caps are
in their proper positions. If covers and caps
are damaged, repair them at once.
• Understand how to use safety equipment
and use it correctly.
• Don’t take down the cab protective guard
without authorization (except machine
maintenance).
2.2.6 Keeping the machine clean
• Clean the wiper, mirror and lamps. Clean

away grass, snow, ice or mud in operation
area, steps and handles in time. Remove
the mud on shoes before entering the
machine.
• Checking and maintaining the machine with
mud or greasy dirt will cause the danger of
slipping, falling or dirt entering eyes. Keep
the machine clean all the time.
CZ335-1102005
• If water enters the electrical system, don’t
hurry to start the power or the engine, which Fig.2-23
could cause machine failure, computer
mainboard damage or other malfunctions.
Don’t wash the electrical system (sensor,
connector etc.) by water or vapor.
2.2.7 Keeping the cab clean
• Please remove the mud and grease on

shoes before entering the cab, or there will
be severe accident caused by slip when
treading the pedal.
• Store scattered objects in the toolbox, and
don’t put them in the cab casually.
• Don’t use mobile phone when operating or
driving the machine.

• Don’t bring dangerous objects such as in-

flammable and explosive materials into the
cab.
2.2.8 Locking of safety lock control lever
• Before standing up from the seat (for pur-

poses such as opening or closing the front
window and skylight, removing or installing
bottom window, or adjusting the seat),
please lower down the work equipment fully
to the ground, firmly turn the safety lock
control lever to the lock position and shut
down the engine. If the control lever or the
pedal isn’t locked, the machine may move
CC13031805
suddenly and lead to serious personal injury
or machine damage. Fig.2-24
• Before leaving the machine, make sure to

lower down the work equipment fully to the
ground, firmly turn the safety lock control
lever to the lock position and shut down the
engine. Lock all equipment with the key,
take off the key and put it in the specified
place.
CZ335-1102074
Fig.2-25
2.2.9 Armrest and ladder
CAUTION
• Face the machine all the time when enter-
ing and leaving the machine.
• Don’t jump up to or down from the ma-
chine, don’t climb it when it travels, and
don’t jump up to it to try to stop it.
• Before entering and leaving the cab, be
sure to check that it is in the front position.

To prevent personal injury due to slipping or

falling down from the machine, please comply
with the following:
• Check the armrest and ladder (including the
track shoe) before entering and leaving the
machine. If there is oil, grease or mud on
the armrest or ladder (including the track
shoe), please clean it away at once and
keep all these parts clean; if these parts are
CZ335-1102008
damaged, please repair them and tighten
the loose bolts. Fig.2-26
• Please use the arrow marked armrests and
ladder shown on the right when entering
and leaving the machine.
• To ensure safety, please face the machine
and keep three body parts (two feet and
one hand or two hands and one foot) touch
the armrests and ladder (including the track
shoe) to support the body.
• Don’t grasp or hold the control lever or lock
lever.
• Don’t enter or leave the machine with tool in
the hand.
• Don’t climb the engine head or cap without
anti-skid mat.
2.2.10 Precautions for working at heights
When working at heights, please use steplad-

der or other brackets to ensure safe
operation.
2.2.11 Keeping clear of the accessory
Don't allow anyone to sit on the work equip-

ment or other accessories because there will
be the danger of falling and severe injury.
2.2.12 Don’t get stuck in the articulation section
The interspace around the work equipment

will change with the movement of the link.

Getting stuck in it will lead to severe injury.

Don’t allow anyone to approach the rotating or
stretching part.
2.2.13 Preventing scald
2.2.13.1 Hot coolant
• To prevent scald caused by squirt of hot

coolant or vapor, please wait for full cooling
of the coolant before checking or draining
the hot coolant.
• Don’t open the radiator cap before the en-
gine cools down. Even the coolant is cold,
be sure to slowly loosen the radiator cap
before removing it to release the internal
pressure of the radiator and prevent severe
CZ335-1102011
scald.
Fig.2-27

2.2.13.2 Hot oil
To prevent scald caused by squirt of hot oil,

please wait for full cooling of coolant before
checking or draining the oil. Even the oil is
cold, be sure to slowly loosen the cap or the
screw plug before removing it to release the
internal pressure.
CZ335-1102012
Fig.2-28
CZ335-1102013
Fig.2-29

2.2.14 Fire and explosion prevention
2.2.14.1 Fire caused by fuel or engine oil
• Fuel and engine oil shall be stored in the

specified place. Don't approach it without
permission.
• Forbid smoking or open fire near fuel and
engine oil.
• Check if the pipe clamp is lost or slack, the
hose is twisty or knotting, hose and pipeline
rub each other, oil cooler is damaged, the
flange bolt of the oil cooler is slack, to pre-
CZ335-1102014
vent fuel/oil leakage; and tighten, repair or
replace any lost, slack or damaged clamp, Fig.2-30
pipeline, hose, oil cooler and its flange bolt.
• Add or store fuel and engine oil in a well-
ventilated place.
• Shut down the engine before refilling.
• Don’t leave the machine when refilling it
with fuel and engine oil.
• Don’t spill the fuel to the overheated surface
or electrical system component.
• Wipe off spilled fuel or engine oil in time
CZ335-1102015
after refilling with fuel or engine oil.
• Place the cleaning cloth with oil or other in- Fig.2-31
flammable materials into the safety contain-
er to ensure the safety of the work site.
• Firmly tighten the fuel and engine oil tank
covers.
• If required, please rinse the components
with nonflammable oil. Do not rinse compo-
nents with diesel or gasoline as it is
inflammable.
• Before conducting grinding or welding oper-
ation on the chassis, make sure to move all
inflammable materials to a safe place.
• Don’t weld the pipeline containing inflam-
mable liquid or cut it through the cutting
torch.

2.2.14.2 Fire caused by inflammable materials
• Eliminate dry leaves, wood chips, paper scraps, dust and other inflammable objects stacking or
sticking around the engine, exhaust manifold, silencer and battery or inside the hood.
2.2.14.3 Fire caused by electrical wire
The short circuit of the electrical system will lead to fire.
• Keep the connector of the electrical wire clean and fix it firmly.
• After operation for 8~10 h, check if the cable or electrical wire is slack, twisty or knotting, hard or
broken; and check if the connector end cap is lost or damaged at the same time.
• When the cable or wire is slack, twisty or knotting, firmly tighten the slack connector or wire
clamp, straighten out the routing, and repair or replace damaged electrical wire.
2.2.14.4 Fire caused by hydraulic circuit
• Check if all clamps, caps and cushions of hoses and pipeline are fixed in the right places.
• If any is loose, it will vibrate and rub with other components, leading to hose damage, high pres-
sure oil squirt, which will cause fire hazard or severe injury.
2.2.14.5 Fire caused by lighting equipment
• Make sure to use explosion proof lighting equipment when checking fuel, engine oil, battery
acid, window cleaning solution or coolant. Otherwise, there will be the danger of explosion, lead-
ing to severe injury.
• When using the electric power of the machine as the lighting, please follow the regulations in this
manual.
2.2.14.6 Fire caused by heat shield
• Lost or damaged heat shield will cause fire.

• If any abnormalities are discovered, please repair or install a new heat shield before operation.
2.2.15 Actions in case of a fire
If there is a fire, please leave the machine

quickly as per the following requirements.
• Turn the starter switch to OFF position to
shut down the engine.
• Leave the machine by the armrest and
ladder.

2.2.16 Windshield cleaning solution
Please use ethanol-based cleaning solution

instead of methanol-based cleaning solution
as the later one can hurt eyes.
2.2.17 Preventing flying components
The grease in the track tensioning regulating

device is under high pressure, therefore if the
following precautions aren't observed, acci-
dents of severe injury, blindness or death may
occur:
• Don’t remove grease nozzle or valve com-
ponents because they may fly off. Please
keep the body and face away from the
valve.
• Pressure exists inside the travel drive CZ335-1102016
assembly. Fig.2-32
• Gear oil is hot, so make sure to wait for
cooling of gear oil before gradually loosen-
ing the air exhaust plug to release pressure.
Because parts may fly off, please keep the
body and face away from the air exhaust
plug to avoid injury.
2.2.18 Prevent falling, flying and invading objects
On the dangerous work site where falling, fly-

ing and invading objects would hit or enter the
cab, install necessary protection shield to pro-
tect the operator according to the operation
conditions.
• When conducting removal or breaking oper-
ation, install front protection shield and
paste transparent cellophane on the front
window.
• When operating in a mine or quarry with the CZ335-1102017
risk of rock falling, install FOPS (Falling Ob- Fig.2-33

ject Protective Structures) and front protec-
tion shield, and paste transparent
cellophane on the front window; and

operator shall wear helmet and protective

glasses.
• When conducting the above operation,
please close the front window. In addition,
ensure that other workers keep proper
safety distance from the falling hazard
zone.
• The conditions described above are typical
working conditions, and there may be other
protective shields required to install based
on the site conditions. Please contact the
agents authorized by Sany Heavy Machi-
nery Co., Ltd. in advance.
2.2.19 Accessory installation
• Issues of safety or legal restraint are existing for installation of options or accessories. There-
fore, please contact the agents authorized by Sany Heavy Machinery Co., Ltd.
• For any injury, accidents or product malfunction caused by use of unapproved accessory or part,
Sany Heavy Machinery Co., Ltd takes no responsibility.
• When installing and using purchased accessory, please read the instruction manual of related
accessory and the general instruction of related accessory in this manual.
2.2.20 Accessory combination
Different types or combinations of work equipment may lead to the danger of colliding with the cab
or other parts of the machine. Before using unfamiliar work equipment, please check if there is the
danger of collision and be careful to operate.
2.2.21 Cab window glass
• If the cab window glass near the side of the work equipment is damaged or broken, there will be
the danger of the work equipment touching the operator’s body. In that case, please stop opera-
tion at once and change glass.
• If the skylight is damaged and fails, please replace it with new glass.
2.2.22 Unauthorized retrofit
Machine retrofit, unauthorized by Sany Heavy Machinery Co., Ltd, may lead to safety issues and
personal injury. Retrofit will have severe influence on the strength and view of the machine. Before
any retrofit, please contact the agents authorized by Sany Heavy Machinery Co., Ltd. For any

accident, malfunction or damage caused by unauthorized retrofit, Sany Heavy Machinery Co., Ltd
will take no responsibility.
2.2.23 Site survey in advance
• During operation near such inflammable

materials as grass roof, dry leaves or dry
grass, there will be the danger of fire, so
please be careful during operation.
• Check the terrain and ground conditions of
the work site and determine the safest oper-
ation methods. Don’t operate the machine
in dangerous zones of landslide or rock fall.
• During operation in dangerous areas such
CZ335-1102018
as near-ditch area or road shoulder, please
reinforce the ground based on the actual Fig.2-34
need and keep the safety distance from the
machine to the near-ditch area or road
shoulder. Assign a signalman to command
when necessary to prevent casualty.
• If there are pipelines such as water pipe,
gas pipe, cable or high voltage electrical
wire buried under the ground, please con-
tact related public administration depart-
ments and mark the positions before
CZ335-1102019
operation and pay attention not to breaking
or damaging any pipeline. Fig.2-35
• Take necessary measures to prevent any-
one without access permission from enter-
ing the operation area. During operation on
the road, please assign a signalman to in-
stall a retaining plate to ensure smooth traf-
fic and pedestrian safety.
• During operation on the frozen ground,
please be cautious, because the increasing
environment temperature will make the
foundation soft, wet and slippery.
• When the machine travels or is operated in
shallow water or soft ground, please check
the type and conditions of the bedrock as
well as the depth and flow rate of water.

2.2.24 Operation on loose ground
• Avoid the traveling and operation of the ma-

chine near the cliff, on the road shoulder
and deep ditch. In these areas with soft
ground, there is the danger of the machine
falling or rollover because of the weight of
the machine and vibration. Please notice
that the ground will be much softer after
heavy rain, blasting or earthquake.
• During operation on the dam or near the
digging ditch, there is the danger of ground
subsidence because of the weight of the
machine and vibration. Before operation,
please take measures to ensure ground
safety and prevent machine rollover or
falling.

2.2.25 Don’t approach high voltage cable
Don’t operate the machine or control it to trav-

el near the cable, as there may be the danger
of electric shock, which will lead to equipment
damage or casualty. Please operate the ma-
chine as per the following steps in the work
site near the cable:
• Before operation in the work site near the
cable, please inform the local electric power
company and ask the company to take nec-
CZ335-1102020
essary measures.
• There is high possibility of electric shock if
Fig.2-36
the machine stays close to the cable, which
leads to severe burn and even death. Cable Voltage Safety Distance
Please keep the safety distance from the 100V-200V More than 2 m ( 7 ft)
machine to the cable (see the right table). 6,600V More than 2 m ( 7 ft)
Before operation, please consult with the lo-
22,000V More than 3 m ( 10 ft)
cal electric power company about meas-
66,000V More than 4 m ( 14 ft)
ures of safety operation.
• If the machine stays close to the cable, a 154,000V More than 5 m ( 17 ft)
signalman shall be assigned to command. 187,000V More than 6 m ( 20 ft)
• Don’t allow anyone to approach the ma- 275,000V More than 7 m ( 23 ft)
chine during operation near the high voltage
500,000V More than 12 m ( 36 ft)
cable.
• When the machine stays close to the cable
or touches the cable, the operator shall not
leave the cab before verifying the cable is
cut off to avoid electric shock. In addition,
don’t allow anyone to approach the
machine.
• To prevent accidents, please wear rubber
shoes and gloves before operation. Cover a
layer of rubber pad on the seat and pay at-
tention to ensuring that exposed parts of
the body will not touch the lower part of the
machine.

2.2.26 Ensuring favorable view
This machine is equipped with a rearview mir-

ror to improve the view; but even with it, also
there are places unseen from the seat. There-
fore, be cautious during operation.
Before operating the machine in a place with

bad view, make sure to verify the conditions of
the work site or the obstacles around the ma-
chine; otherwise machine damage or personal
injury may occur. Please strictly observe the
following precautions when operating the ma-
chine in a place with bad view:
• Before operation every day, please check
the rearview mirror. Clean it and adjust the
view range to ensure favorable view.
• During operation in dim places, turn on the
work light and the front lamp of the machine
and install auxiliary lighting in the working
region if necessary.
• Stop operation if favorable view can’t be
guaranteed, such as days of fog, snow, rain
or sand wind.
• Install signs on the road shoulder or soft
ground. When the view is bad, assign a sig-
nalman if necessary. Operator shall pay
great attention to the signs and follow sig-
nalman’s command.
• Ensure all workers understand all signals
and gestures before operation.

2.2.27 Ventilation of working environment
• Exhaust gases from the engine can be

deadly, therefore if it is necessary to start
the engine, or deal with fuel, cleaning oil or
paint in a closed zone, the door and window
shall be open to ensure sufficient ventilation
for preventing gas poisoning.
• Do not operate the machine in the environ-
ment of toxic gas or underground; if neces-
sary, please wear gas mask and ensure
CZ335-1102022
ventilation.
Fig.2-37
2.2.28 Prevention of asbestos dust
Inhaling asbestos dust from the air would lead

to lung cancer. There is the danger of inhaling
asbestos when workers are engaged in re-
moval operation or handling industrial waste.
Please observe the following rules:
• During cleaning, reduce dust by spraying
water, and don’t clean by compressed air.
• If there is asbestos dust in the air, please
operate the machine in the windward posi-
tion. Every worker shall wear dust mask.
• Don’t allow anyone to approach the ma-
chine during operation.
• Please observe the local regulations, rules
and environment standards.
WARNING
• This machine uses no asbestos, but coun-
terfeit parts may contain asbestos. Vastly
inhaling asbestos may harm lung or lead to
death. Therefore, please use genuine
parts of Sany Heavy Machinery Co., Ltd.

2.2.29 Cab emergency exit
• If the cab door can’t be opened for some

reason, use the safety hammer to break the
window, creating an emergency exit.
• For escape, remove all glass fragments in
the window frame firstly and be careful not
to be hurt by glass. Also, be careful not to
slip because of glass fragments.
A820601990969
Fig.2-38
2.3 Safe machine operation

2.3.1 Start
2.3.1.1 Boarding the machine safely
When you come into and leave the machine:

• Face the machine and keep three body
parts (two feet and one hand or two hands
and one foot) touch the machine.
• Don’t jump up to and down from the ma-
chine, and don’t climb it when it runs.
• Don’t take any control levers as the
armrest.
• Mud, greasy dirt and water on all pedals,
CA13031506
armrests and shoes shall be cleaned away
at any time. Fig.2-39
• Before entering and leaving the cab, it must
be in the front position.

2.3.1.2 Seat adjustment
Uncomfortable seat position may easily make

the operator tired, leading to wrong operation.
Every time the machine operator changes,
the operator shall readjust the seat position.
When the operator backs against the back-
rest, he/she shall be able to step on the pedal
to the floor and correctly operate the joysticks.
Otherwise, move the seat forward and back-
ward to readjust it.
Fig.2-40
2.3.1.3 Fastening seat belt
When rollover accident occurs, operator may

be hurt or thrown out of the cab, or likely to be
squashed by the machine, leading to severe
casualty accident. Before operation, please
check the safety belt, buckle and fixture care-
fully. The safety belt or its components, if
damaged or worn, shall be replaced before
operation. Please sit on the seat and fasten
the safety belt during the running process of
the machine to avoid accident. CZ335-1102027
It’s best to replace the safety belt once three Fig.2-41

years regardless of its service condition.

2.3.1.4 Inspection before engine start
Before starting the daily work, please check

the followings before starting the engine:
• Wipe off dust on the window glass surface
to ensure favorable view.
• Wipe off dust on the lens surfaces of the
front lamp and work light and check if the
work light works well.
• Check the engine coolant level, fuel and en-
gine oil level.
• Check if the air cleaner is blocked. CZ335-1102028
• Check if the electrical wire is damaged. Fig.2-42

• Adjust the seat to the position which is easy
for operation and check if the seat belt and
fixture are damaged or worn.
• Check if the instruments work well, check
the angle of the work light and check if all
control levers are in the neutral position.
• Check if the safety lock control lever is in
the lock position.
• Adjust the rearview mirror so as to clearly
see the rear of the machine from the cab
seat.
2.3.1.5 Starting the machine safely
For the correct start steps, see the instruction

about starting machine in the Section
Operation.
• Before starting the machine, ensure no peo-
ple stays on, below and around the ma-
chine and press the horn button to give the
start warning.
• Sit on the driver’s seat and adjust it until
you feel comfortable to operate all control
devices.
• Be familiar with all warning devices, instru-
CZ335-1102029
ments and operational control devices. Fig.2-43

• Set all control devices to the neutral /park-
ing position.

• Don’t allow anyone to stay on the machine

except for the operator.
• Please strictly observe the instruction of the
Section Operation in this manual to start the
engine. Don’t follow the way that will cause
the motor short circuit to start the engine.
WARNING
• When it is necessary to start the engine or
operate the machine in a closed environ-
ment, please ensure sufficient ventilation.
Inhaling too much tail gas could lead to
death.
• If you cannot shut down the machine,
please do not start it.
2.3.1.6 Engine start in cold weather
• Warm up the engine fully. If the engine isn’t fully warmed up, operation of joysticks will be re-
sponded slowly by the machine, leading to accidents.
• Check if the battery acid is frozen or leaks before starting. If the battery acid is frozen, don’t
charge the battery or start the engine by different electric power. In that case, please melt the
battery acid firstly, otherwise the battery may be on fire.
2.3.1.7 Required auxiliary equipment for start
Please follow the instruction in the operation manual when starting the engine by connecting auxili-
ary cable. Incorrect operation will lead to battery explosion or the machine out of control, and
cause casualties. It is forbidden to start the engine by auxiliary cable without permission. Please
contact the agents authorized by Sany Heavy Machinery Co., Ltd. if necessary.
• 2 persons are needed to cooperate to start the engine by auxiliary cable (one sits on the driver's
seat and the other operates the battery).
• Please wear goggles and rubber gloves before starting the engine by auxiliary cable.
• When connecting the normal machine with the machine with malfunction by auxiliary cable, the
battery voltage of the former shall be the same as that of latter. Meanwhile, please pay attention
not to making two machines contact each other.
• Turn the ignition switches of the normal machine and the machine with malfunction to OFF posi-
tion when connecting auxiliary cable. Otherwise when the power is on, the machines may move
and pose a risk.
• Please make sure to connect the positive pole (+) at first, when connecting the auxiliary cable.
Please disconnect the grounding or the negative (-) cable (grounding side) when removing the
auxiliary cable.
• When removing the auxiliary cable, be careful not to make the auxiliary cable clamps contact
each other or the cable clamps contact the machine. As diethyl ether cold starting fluid is ex-
tremely inflammable and explosive, please read the instructions on the container before use.
Don’t use diethyl ether when the engine is equipped with glow plug preheater or other types of
preheater.
2.3.1.8 After starting the engine
After the engine is started, idle it for 3~5 min, and observe the system parameters displayed in the
instruments to ensure the instruments function well and each reading is in normal operational
range.
2.3.2 Operation
2.3.2.1 Inspection before operation
• Move the machine to a wide zone without

obstacle, slowly operate it and allow no one
to approach during the check.
• Please fasten the seat belt.
• Check if the instruments and equipment are
working properly and check if the bucket,
arm, boom, travel system, swing system
and steering system function well.
• Check if the sound, vibration, heating, odor
or instruments of the machine are normal,
and check if there is leakage of engine oil or
fuel.
• Test the engine speed control device with
the travel control lever placed in the neutral
position; operate the control lever of every
device to check that each device functions
well and know the control mode of the work
equipment.
• If any abnormalities are discovered, don’t
continue to operate the machine but repair
it at once.

CAUTION
• Observe and carefully listen to the ma-
chine to check for any abnormality. If any,
stop the machine at once. Before further
operation, please resolve the malfunction
at once and report to the superior.
2.3.2.2 Precautions before operation
To prevent severe personal injury or death,

please pay attention to the followings before
operation:
• The turning circle of a 12 m radius is the
working area (hazard zone) of the machine.
Please press the horn button to warn the 12
m
workers in this area before operation.
• No one shall be on, near the machine or in
the turning circle.
• To ensure the view in the travel direction,
CZ215S-1102003
please turn the cab if necessary. Fig.2-44

• Please assign a signalman in the place with
bad view.
2.3.2.3 Verifying the travel direction
• Verify the position of the lower structure rel-

ative to the operator before driving the
machine.
• Pushing the joystick forward/stepping on
the pedal should move the machine for-
ward, when the guide wheel is under the
front of the cab.
• Pushing the joystick forward/stepping on
the pedal should move the machine back-
CZ335-1102031
ward, when the travel motor is under the
front of the cab. Fig.2-45

There is a travel direction sign inside the lower

structure. When the operator pushes the joy-
stick forward/steps on the pedal, the arrow on
the sign points to the actual travel direction of
the machine.
NOTE：
In this manual, front, rear, left and right refer
to the direction seen from the cab when the
cab faces the front while the driving wheel is
in the rear of the machine.
Fig.2-46
WARNING
• Wrong operation of travel control lever/
pedal may lead to severe accident.
2.3.2.4 Safety rules for changing the machine direction
• Operate the machine only when you are

seated.
• Don’t allow anyone on the machine except
for the operator.
• Check if the travel warning device functions
well.
• The door and window of the cab shall be
locked in the opening/closing position. At
the work site where there is the danger of
CZ335-1102033
falling or flying objects entering the cab,
please check if the door and window are Fig.2-47
closed tightly.
• Check that there is no one or obstacle in

the working area and press the horn button
to give warning before reversing or swing.
• Be cautious to check if anyone enters the
working area of the machine. Pay greater
attention not to contacting other machine or
person when the machine makes a turn or
swings.
CZ335-1102034
Fig.2-48

• Adjust the machine before traveling to place

the driving wheel in back of the driver's
seat. When the driving wheel is in the front
of the cab, the machine will move in the op-
posite direction of the operation of the joy-
stick (i. e. forward and backward operation
for backward and forward travel, and right-
ward and leftward operation for left and
right turn). Please pay greater attention in CZ335-1102035
case of that.
Fig.2-49
• Please assign a signalman to command

and keep the signalman in the view, when
your view is hindered during reversing;
• When a signalman is required under specif-
ic working conditions, please adopt hand
signals in accordance with local
regulations;
• Only when both the signalman and the op-
erator know well the signals can the ma-
CZ335-1102045
chine be moved;
• Understand the meaning of all flags, signals Fig.2-50
and marks in work and confirm who is in
charge of signaling;
• Keep the window, rearview mirror and work
light clean and in good condition;
• Dust, heavy rain, fog and etc. will reduce
visibility. Please slow down and use proper
lighting when the visibility reduces.
WARNING
• If someone is near the machine during re-
versing or swing of upper structure, he/she
may be knocked down or squashed by the
machine, leading to severe accident.

2.3.2.5 Travel safety rules
• To prevent engine stall because of overload

and work equipment damage during opera-
tion, don’t exceed the maximum allowable
load or performance parameters of the
machine.
• Please keep the safety distance from peo-
ple, buildings and other machines to pre-
20~30cm
vent collision during traveling or operation. (8~12i n)
• Please contact relevant departments and

CZ335-1102036
follow their guidance when traveling on the
road. Fig.2-51
• When the machine travels on a flat ground,
make sure to retract the work equipment
and keep a 20~30 cm (8~12 in) height
above the ground.
• The machine shall travel at a low speed on
the rough ground and not make a turn sud-
denly, otherwise the machine may roll over.
If the work equipment hits the ground, the
machine will lose balance and be damaged.
• For traveling on the rough ground or steep

slope, if the machine has a function of auto-
matic idling, turn off the automatic idling
switch (cancel the function); if the switch is
turned on, the engine speed will reduce and
travel speed will slow down abruptly.
• Avoid traveling on the obstacle as far as
possible; if it’s necessary, lower down the
work equipment to approach the ground
CZ335-1102037
and move the machine at a low speed.
• Before passing over a bridge or structure, Fig.2-52
check if the structure strength is able to
support the machine weight firstly.
• During operation in areas with limited height
such as in tunnel, under bridge and under
electrical wire, slowly operate the machine
and pay greater attention not to making the
work equipment contact any other objects.

2.3.2.6 Driving the machine safely
• Verify the guide wheel is under the front of

the cab and clearly know how to move the
joystick or step on the pedal before driving
the machine.
• Step on the forepart of the travel pedal or
push forward the travel control lever to
move the machine towards the guide
20~30cm
wheel. (8~12i n)
• When traveling on a slope, please keep the
CZ335-1102038
work equipment 20~30 cm (8~12in) above
the ground. In case of emergency, lower Fig.2-53
down the work equipment to the ground
rapidly to help stop the machine.
WARNING
• Traveling on a slope may lead to slip or
rollover, causing severe accident.
• For uphill traveling, adjust the cab to make

it face the uphill direction; for downhill trav-
eling, adjust the cab to make it face the CZ335-1102039
downhill direction.
Fig.2-54
• Please check the hardness of the ground in
front of the machine before traveling.
• When running up a steep slope, extend the

work equipment forward for keeping bal-
ance and keep it 20~30cm (8~12in) above
the ground, and move the machine at a low
speed.
• When running down a slope, reduce the en-
gine speed, keep the travel control lever
near the neutral position and move the ma-
chine at a low speed.
CZ335-1102040
Fig.2-55

• Straightly travel uphill and downhill, be-

cause it’s extremely dangerous to make a
turn on the slope or cross the slope.
CZ335-1102041
Fig.2-56
• Don’t make a turn on the slope or cross the

slope. Make sure to move the machine
down to a flat ground, change the machine
position, and then drive the machine uphill.
• Travel at a low speed on ground with grass,
fallen leaves or wet steel plate. There may
be the danger of slip even on a gentle
slope.
• If the engine stops when the machine trav- CZ335-1102042
els on a slope, please move the joystick to

the neutral position immediately and restart Fig.2-57
the engine.
2.3.2.7 Operation on slope
During operation of the upper structure or

work equipment of the machine on a slope,
there will be the danger of losing balance and
rollover, which may lead to severe injury or
equipment damage. These operations shall
be done on a flat work platform and with care.
• When the bucket is fully loaded, don’t swing
the work equipment from the uphill side to
the downhill side. This operation is danger-
ous and may lead to machine rollover. CZ335-1102046
• When the machine must be used on a

Fig.2-58
slope, please build a work platform with soil
to keep the machine horizontal as far as
possible.

2.3.2.8 Operation in snowy weather
• During traveling or operation on a highly

slippery snow-covered and frozen ground,
please do not operate the control lever
abruptly; pay greater attention especially
during operation on a slope, because the
machine may slip even on a gentle slope.
• For frozen ground, it will be soft after the
temperature rises up, leading to machine
rollover.
• When the machine travels over deep snow,
there will be the danger of rollover and
being buried in snow. Pay attention not to
leaving the road shoulder and getting stuck
in snow.
• When cleaning the snow, it’s hard to see
the road shoulder and objects near the road
buried in snow. There will be the danger of
rollover and colliding with buried objects.
Therefore, be careful to operate the ma-
chine in that case.
2.3.2.9 Forbidden operation
• Don’t excavate the working surface under

the suspending part. Otherwise, there will
be the danger of rock falling, even leading
to collapse of the suspending part and se-
vere accident.
CZ335-1102047
Fig.2-59

• Don’t excavate the front area under the ma-

chine too deep. Otherwise, after the under-
neath part is hollowed out, the ground will
collapse and lead to accident.
CZ335-1102048
Fig.2-60
• Don’t conduct removal operation under the

machine, which makes the machine unsta-
ble and face the danger of rollover.
• Before operation over the buildings or other
structures, please check the structure
strength to prevent casualty due to collapse
of structure.
CZ335-1102050
Fig.2-61
• When conducting removal operation, don’t

remove the part immediately above. Frag-
ment falling down and structure collapse will
lead to machine damage and casualties.
CZ335-1102051
Fig.2-62

• Don’t break the target by the impact force of

the work equipment; otherwise scattering
fragment material may hurt people and
damage the work equipment, and also the
impact reaction may lead to machine
rollover.
• Generally speaking, the work equipment on
the side of the machine is easier to turn
over than the one in the front or the back. CZ335-1102052
Fig.2-63
• Lifting, moving or swing of the bucket must

not pass above anyone or the truck cab. If
the materials in the bucket fall down or the
bucket hits something, personal injury or
machine damage may occur.
• Never lift or transport people with the ma-
chine, which may lead to casualty.
• The machine with breaker or other heavy
work equipment has the danger of losing CZ335-1102053
balance and rollover.

• Don’t suddenly lower down, swing or stop Fig.2-64
the work equipment.
• Don’t suddenly extend or retract the boom
cylinder; otherwise, there will be the danger
of rollover because of the impact force.

2.3.3 Parking
2.3.3.1 Choosing parking lot
• Park the machine on a solid and flat

ground.
• Choose a safe region without risk of falling
rock and collapse etc to park the machine.
For low-lying area, park the machine at the
place without flood risk.
CZ335-1102054
Fig.2-65
• Park the machine on a level ground as far

as possible. If it's necessary to park it on a
slope, following rules must be observed:
• Adjust the bucket to make it face the down-
hill side and insert the bucket tooth into the 120°
ground.
• Place a cushion block under the track to
prevent machine movement.
CZ335-1102055
Fig.2-66
• Don’t park the machine on a construction

road. If it’s necessary, please comply with
local rules to reminder other people or ve-
hicles by flag in the daytime and signal lamp
at night.

2.3.3.2 Machine shutdown
See the Section Operation of this Manual for

detailed machine shut down steps. General
shutdown procedure is as follow:
• Stop the running machine.
• Adjust the body.
• Lower the work equipment to the ground or
place it at fixed position.
• Slow down the engine and run it at a low
idle speed for 5 min.
CZ335-1102074
• Turn the ignition switch to [OFF] position to
stop the engine. Fig.2-67
• Pull the safety control lever to the lock
position.
• Take out the ignition key.
• Close the window, skylight and cab door.
• Lock all access doors and boxes.
NOTE：
• When you leave the machine, please keep
three-point contact and face the machine,
and don’t jump down from the machine. CZ335-1102028
• When leaving the machine, be careful of

Fig.2-68
the smooth track, steps and handles.
2.3.4 Transportation
2.3.4.1 Transportation
When transporting the machine, pay attention

to the followings:
• Know the overall length, width and height of
the transport vehicle and the machine and
avoid contacting the obstacles at a high
place and narrow channel.
• Before passing the bridge, please check if
the bridge is able to support the weight in
advance; when driving on road, please fol-
low traffic laws and traffic police’s
command.

2.3.4.2 Loading and unloading
During loading and unloading, wrong opera-

tion will lead to machine rollover and falling
down, therefore pay attention to the
followings:
• Load and unload the machine on a solid
and flat ground only; keep a safe distance
from the edge of the road or cliff.
• Access board with sufficient strength must
be used. Ensure that the access board is
CZ335-1102059
wide, long and thick enough to form a safe
loading and unloading slope (≤15°). Fig.2-69
• Ensure the access board surface is clean
and without grease, oil, water and scattered
materials and clean dirt on the machine
track. During loading and unloading in rainy
or snowy weather, please be careful of the
wet and slippery access board surface.
• Don’t load or unload the machine by the
work equipment; otherwise machine falling
down or rollover may occur.
• Cancel the function of automatic idling, run CZ335-1102060
the engine at a low speed and slowly drive Fig.2-70

the machine.
• Don’t operate any joysticks except for the
travel control lever on the access board.
• Don’t correct the direction on the access
board. If necessary, drive the machine away
from the access board, correct the direction,
and then drive the machine to the board
again.
• At the connection between the access
board and trailer, the machine center of
gravity will change suddenly, making the
machine liable to lose balance. Therefore,
move the machine slowly when passing this
part.
• For loading and unloading on an embank-
ment or platform, ensure the embankment

or platform has sufficient width, strength

and gradient.
• The trailer where the upper structure is
swung will be instable, therefore, retract the
work equipment and slowly swing the
structure.
• After loading the machine, please lock the
cab door. Otherwise the cab door may open
suddenly during transport.
• Fix the machine by chain and cushion
block. Fix all work equipment, lower down
the bucket, boom and arm, and place them
in the transport position.
2.3.5 Battery
Preventing the danger caused by battery
Battery acid comprises sulfuric acid and is

able to generate flammable and explosive hy-
drogen. Wrong operation will lead to injury or
fire. Therefore, it is important to observe the
following rules:
• No smoking or open flame near the battery.

• Turn the ignition switch to OFF position be-
fore checking or handling the battery. CZ335-1102061
• Please wear safety glasses and rubber Fig.2-71

gloves when handling the battery.
• Battery acid is highly corrosive. If battery
acid splashes on clothes and skin, flush
with plenty of water at once. If it enters your
eyes, there will be the danger of blindness,
therefore make sure to flush with plenty of
water at once and seek for medical care.

To avoid battery explosion, please observe

the following precautions during operation:
• Don’t allow tool or other metal objects to
contact battery terminal; don’t allow tool or
other metal objects to be placed near the
battery.
• For disconnecting the battery, 1 min after
the engine is shut down, disconnect the
negative (-) terminal firstly, and then the CZ335-1102062
positive (+) terminal; For connecting, con-
nect the positive (+) terminal firstly, and Fig.2-72
then the negative (-) terminal. Ensure all
terminals connect well.
• During charging process, when battery tem-
perature exceeds 45℃, stop charging and
lower the temperature to the room tempera-
ture; then half the charging current before
continuing to charge the battery.
• When battery is charging, it will generate in-
flammable hydrogen. Therefore, before
charging, dismantle the battery from the
superstructure, place it in a well-ventilated
place and dismantle the battery cover.
• If acid sprays out of the battery exhaust
hole during charging, please stop charging
at once.
• Never smoke or keep off any fire source
during charging.
• When the battery electrical eye becomes
green, it indicates completion of charging.
In that case, stop charging.
• After charging, screw up the battery cover
tightly.
• Install the battery to specified position
tightly.

2.3.6 Towing
For towing of a damaged machine, incorrect

operation method or choosing nonconforming
wire rope will lead to severe accident:
A
• Don’t tow the machine on a slope.
• Wear protective gloves and helmet when B
using wire rope.
• Check that the wire rope is of adequate C
strength that it can bear the weight of towed
machine.
• Don’t use wire rope having such problems
CZ335-1102063
as broken strand [A], reduced diameter [B] Fig.2-73

and twisting [C]. These wire rope may break
off during towing.
• Don’t stand between the towing machine
and the towed machine during towing.
• Slowly operate the machine and pay atten-
tion not to loading the wire rope suddenly.

2.3.7 Lifting by excavator
• Allow no one to enter the working area.

• Before operation, determine all possible
signals used in operation and assign a
signalman.
• To prevent rollover or falling down, operate
the machine on a flat ground.
• Before lifting, please know the lifting ca-
pacity of the machine, and don’t exceed the
specified lifting load.
CZ335-1102064
• Don’t use damaged chain, wire rope, lifting
eye and brace. Fig.2-74
• Hang the lifting sling on the lifting point
specified by the manufacturer. Never hang
lifting eye or rope on the bucket teeth. Oth-
erwise, the bucket teeth may fall off, leading
to falling down of lifted object.
• Don’t leave driver's seat during lifting.
• To prevent the lifted objects from contacting
people or construction, check if the sur-
rounding area is safe before swinging or op- CZ335-1102065
erating the work equipment.
• Don’t suddenly swing or operate the work Fig.2-75
equipment. This will lead to the swing of the
lifted objects, and even machine rollover.
Use a tow rope to strengthen control if
necessary.
• Don’t tow the load in any directions by the
work equipment or by rotation. Once the lift-
ing hook breaks and load separates from it,
the work equipment will move suddenly and
cause injury.
CZ335-1102066
Fig.2-76

2.4 Safe maintenance instruction

2.4.1 Precautions before maintenance
To prevent accidents:
• Understand the maintenance procedure be-
fore operation.
• Keep the work region clean and dry.
• Don’t spray water or vapor in the cab.
• Never do refueling, lubrication and other
maintenance work while the machine
moves.
• Keep your hands, feet and clothes off the
rotary parts.
2.4.2 Self-preparation
The machine can be maintained or repaired

by approved workers only. An observer could
be assigned if necessary.
• Wear protection suit and safety shoes re-
quired by the work.
• When you remove spring, flexible compo-
nents or add acid to the battery, please
wear face shield. Wear helmets and eye
protection when you weld or cut something.
• During cleaning with compressed air, flying CZ335-1102069
granules may cause personal injury. There- Fig.2-77

fore please wear goggles, dust mask,
gloves and other protective equipment.
• When knocking hard metal part with a ham-
mer, such as pin, bucket teeth, cutting edge
or bearing, parts and metal fragments flying
off will lead to injury. Therefore please wear
goggles and gloves and keep anyone off
the surrounding area.
• Don’t conduct grinding, flame cutting or
welding if breather or ventilation equipment CZ335-1102071
is not available. If it is necessary to perform Fig.2-78

welding on the hydraulic excavator, refer to
relevant manual for correct procedures.

• If the machine creates too much noise, it

may lead to temporary or permanent hear-
ing problem. When maintaining the engine,
please wear ear muff or plug before working
in the noise for a long time.
• Please wear rubber apron and rubber
gloves when contacting corrosive materials.
Please wear protective gloves when han-
dling wooden materials, wire ropes or metal
with sharp edge.
2.4.3 Preparation of working area
• Select a working area with enough space,

sufficient light, good ventilation, clean and
flat ground for maintenance.
• Clean the working ground, wipe off fuel, lu-
bricant and water, and cover the slippery
ground with sand or other adsorptive
materials.
• Don’t leave hammer or other tools in the
working area.
• If you fail to keep the working area clean
and tidy, there will be the danger of stumble,
slip and fall, leading to personal injury.

2.4.4 Steps of engine shutdown before maintenance
Before maintaining the machine:

• Park the machine on a solid and flat
ground.
• Lower down the bucket to the ground.
• Place cushion blocks under the track to pre-
vent the machine from moving.
• Turn the accelerator control knob to "1" po-
sition to run the engine at a low idle speed
and under no load for 5 min.
CZ335-1102054
• Turn the ignition switch to [OFF] position to
stop the engine. Fig.2-79
• Turn the switch to [ON] position and move
the control lever to the front, back, left and
right twice and three times respectively to
release pressure in the hydraulic system.
• Take off the key from the ignition switch.
• Turn the safety lock control lever to “LOCK”
position.
CZ335-1102074
Fig.2-80

2.4.5 Warning decal
• Hang up “No Operation” decal or similar

warning decal on the ignition switch or di-
rection control device before maintenance
to warn others that the machine is under
maintenance.
If necessary, an additional warning decal
can be attached around the hydraulic
excavator.
• If someone starts the engine, contacts and
CZ335-1102067
operates the control lever or pedal during
maintenance, it will lead to severe accident. Fig.2-81
CZ335-1102068
Fig.2-82
2.4.6 Proper tools
• Only proper tools can be selected for main-

tenance and they shall be used correctly;
using damaged, bad, defective and tempo-
rary tools or incorrectly using tools will lead
to severe accident.
CZ335-1102072
Fig.2-83

2.4.7 Maintenance during engine running
Don’t maintain the machine when the engine

runs to prevent injury. If necessary, the main-
tenance during engine running requires at
least 2 workers and shall be conducted as the
followings:
• One worker must sit in the driver’s seat all
the time and be ready to shut down the en-
gine at any time. All workers must keep in
touch.
• Turn the safety lock control lever to "LOCK" CZ335-1102028
position to prevent the work equipment from Fig.2-84

moving unexpectedly.
• Operation near the fan, fan belt or other ro-

tary components will cause the danger of
being rolled by the components. Please pay
greater attention to it.
• Tools or other objects shall not fall into fan
or fan belt, otherwise, parts will be broken
or fly off.
• Don’t touch any control levers. If necessary,
please signal others and warn them to
CZ335-1102077
move to a safe place.
• In case the high pressure common rail pipe Fig.2-85
is leaky, never do maintenance on the exca-
vator when it is operating; or during normal
operation, never remove or install any high
pressure components.

2.4.8 Operation under the machine
• Don’t maintain the machine before well sup-

porting it.
• Lower down the work equipment to the
ground before maintenance.
• If the machine or the work equipment must
be lifted for maintenance, support it firmly
with cushion block or bracket of sufficient
strength , rather than slag brick, cord tyre or
shelf; don’t support the machine by a single
CZ335-1102078
jack.
• If the track shoe leaves the ground while Fig.2-86
the machine is only supported by the work
equipment, it’s very dangerous to operate
under the machine. If the hydraulic pipeline
is damaged or the control lever is contacted
by accident, the work equipment or ma-
chine may fall down suddenly, causing
casualty. Therefore never work under the
hydraulic excavator if it is not firmly sup-
ported by the cushion blocks or brackets.
2.4.9 Track maintenance
• Due to dry friction, the track pin and track

bushing are very hot. To prevent scald,
please wear safety protective gloves.
• Keep proper track tension. During operation
on mud and snow ground, mud and snow
will stick to the track parts, making the track
too tight. In that case, please adjust track
tension according to the operation manual
of the product.
• Check if the track shoe is loose or broken,
and if the track pin and the track bushing
are worn or damaged, and check the track
roller and the carrier roller.

CAUTION
• Don’t knock the track tension springs, as
they may bear huge pressure and break
suddenly, leading to injury. Don’t remove
springs under compression condition. Ten-
sion spring should not be compressed.
• Follow the track maintenance guidance
provided by the manufacturer.
2.4.10 Safety precautions for track tension adjustment
• Grease is pressed into the track tension ad-

justment system under a high pressure
condition.
• To loosen track tension, slowly loosen the
grease drain plug and don’t unscrew it for
more than one turn.
WARNING
• Failure to follow the specified maintenance
CZ335-1102080
process during adjustment will cause flying
off of the grease drain plug, leading to se- Fig.2-87
vere injury or damage.
• Keep your face, hands, feet or other parts
of the body off the drain hole of the grease
drain plug.
2.4.11 Don’t remove the buffer spring
Buffer spring assembly is used for reducing

the impact force of the guide wheel. It com-
prises a high pressure spring, which, if incor-
rectly removed, will cause flying off of the
spring, leading to severe casualty. If the buffer
spring assembly must be removed, please
contact the agents authorized by Sany Heavy
Machinery Co., Ltd. to conduct this operation.
CZ335-1102081
Fig.2-88

2.4.12 Be careful of hot cooling system
As temperature of engine increases, pressure

in cooling system builds up. Stop the engine
to allow the system to cool down before re-
moval of radiator cap. You should not remove
it until the coolant cools down.
WARNING
• Contacting hot high pressure coolant will
cause severe injury.
CZ215L-1102001
Fig.2-89
2.4.13 Safe operation of high pressure hose
If leakage is found in the high-pressure hose,

it may cause an operational failure and even
lead to a fire. If bolts on the hose come loose,
stop working and tighten the bolts to specified
torque. If any damage is discovered in the
hose, please stop operation at once and con-
tact the agents authorized by Sany Heavy Ma-
chinery Co., Ltd.
Replace the hose at once when the following

problems are discovered:
• Hydraulic tube connectors are damaged or
leak.
• The covering is worn or broken, or steel
wire of the reinforcement layer is exposed.
• Some parts of the covering swell.
• There are impurities inside the covering.
• Removable parts are twisty or squashed.

2.4.14 Be careful of high pressure liquid
Pressure always exists in the hydraulic sys-

tem. When you check or replace the hose, al-
ways check if pressure in the hydraulic oil line
has been relieved. If there is remaining pres-
sure in the hydraulic oil line, serious accidents
will occur. Therefore, it is important to observe
following rules:
• Release system pressure before maintain-
ing the hydraulic system;
1. Screw off the butterfly nut of the breather

valve, and press the exhaust button to re-
lease the internal pressure in the hydraulic
tank.
2. Release pressure in pilot lines group. In

15 seconds after shutdown, turn the ignition
switch to ON position, set the safety lock
control lever to "UNLOCK" position, and
CZ335-1102082
move the travel control lever and the left
and right joysticks to all directions to re- Fig.2-90
lease pressure in the accumulator.

• Keep the hydraulic system off any open
flame, and eliminate splashing hydraulic oil,
if any, at once.
• Diesel or hydraulic fluid under pressure is
able to penetrate skin or eyes, leading to
severe injury, blindness or death. It is diffi-
cult to check if the pressurized hydraulic oil
leaks with naked eyes. You need to find
leakage with a piece of cardboard or wood
chip instead of touching leaked oil directly.
Wear a face mask or protective goggles to
protect your eyes. If oil penetrates your
skin, rinse it with water and seek medical at-
tention as soon as possible.
• When the engine is running, high pressure
will arise inside the fuel pipeline. Before

checking or maintaining the fuel pipeline

system, wait at least 30 seconds after the
engine is shut down, to allow the internal
pressure of the system to reduce.
2.4.15 Welding operation
There is a risk of fire or electric shock during

welding, therefore, welding must be carried
out by qualified welders with appropriate
equipment. Unqualified personnel are not al-
lowed for welding.
CAUTION
• Before welding, disconnect the negative
breaker and the connection of the platform
grounding point (as shown on the right) at
Fig.2-91
the same time; during welding, make the
ground of the welder grounded near the
welding point.
2.4.16 Safe maintenance of HVAC group
WARNING
• R134a refrigerant is a non-toxic gas at
room temperature, but it turns into a highly
toxic gas when it exposes to fire.
• Keep the HVAC group away from fire

source during maintenance.
• Please use the refrigerant correctly accord-
ing to the instruction on the refrigerant con-
CZ335-1102083
tainer when maintaining the HVAC group.
Use R134a as the refrigerant. Don’t use Fig.2-92
other refrigerants. Otherwise, the HVAC
group will be damaged.
• If the refrigerant enters eyes, it may cause
blindness; if it splashes on skin, it will cause
cold injury.
• It is strictly forbidden to discharge the refrig-
erant directly into the atmosphere, instead,

a refrigerant circulation system should be

used.
2.4.17 Precautions related to high voltage
• When the engine is running or was just shut

down, high pressure will arise in the injector
terminal and inside the engine controller,
causing the danger of electric shock. There-
fore, please don't contact the injector or the
inside of the engine controller.
• If it’s necessary to contact the injector termi-
nal or the inside of the engine controller,
please contact the agents authorized by
CZ335-1102084
Sany Heavy Machinery Co., Ltd.
Fig.2-93
2.4.18 Accumulator
The accumulator is filled with high-pressure

nitrogen, thus improper operation to the accu-
mulator may cause an explosion, which may
lead to serious accidents. Therefore please
comply with the following precautions:
• Don’t disassemble the accumulator.
• Keep the accumulator off fire source or do
not expose it to fire.
• Don’t punch, weld or cut by torch the
CZ335-1102085
accumulator.
• Don’t collide with or roll the accumulator, or Fig.2-94
make it suffer any impact.
• Deflation is required for handling of the ac-
cumulator. Please contact the agents au-
thorized by Sany Heavy Machinery Co., Ltd
to conduct this operation.

2.4.19 Preventing the danger of fire and explosion
WARNING
• Don’t smoke when handling fuel or maintaining the fuel system, as fuel vapor in the
empty fuel tank is highly liable to explode. Don't conduct cutting and welding operation
on the fuel pipe, fuel tank or other fuel containers. Otherwise fire and explosion may oc-
cur, leading to casualties.
• Please shut down the engine and turn off the electrical equipment when refueling the tank. Be
extremely cautious when refueling the hot engine. Avoid any spark around the grounding fuel
nozzle.
• Please handle all solvents and dry chemicals according to the steps marked on the containers in
a well-ventilated place.
• Clean away dust and residues on the machine, and don’t place greasy cleaning cloth or other in-
flammable materials on it.
• Please clean parts with non-inflammable solvent rather than gasoline, diesel or other inflamma-
ble liquid.
• Store inflammable liquid and materials in proper containers according to safety regulations.
• Check if fire extinguisher, fire extinguishing system and fire detectors (if equipped) are ready for
use.
2.4.20 Regular replacement of safety related parts
• To ensure long-term safe operation of the machine, parts related to safety such as hose, seat
belt must be replaced regularly.
• Exceeding the specified replacement interval may cause aging problem of part materials. Over-
use will lead to abrasion and damage, causing machine malfunction and personal injury. At the
same time, it’s hard to identify how long these parts can work well only through visual inspection
or touch. Therefore regular replacement is necessary.
• Safety related parts, if defective, shall be replaced or repaired even before the specified replace-
ment interval.
2.4.21 Maintenance operation
• Check all components and parts and replace worn, broken and damaged ones during repair. Ex-
cessively worn and damaged components and parts will be inoperative during the operation of
the machine, causing casualties. Replace damaged or illegible signal marks.
• Screw down all fasteners and connectors to specified torque.
• Install all guards, covers and shields after maintenance. Damaged guard boards shall be re-
placed or repaired. The system shall be refilled with the hydraulic fluid approved or suggested
by Sany Heavy Machinery Co., Ltd only.

• Start the engine and check leakage condition (check the hydraulic system); then operate all con-
trol devices to confirm all functions of the machine are in well condition. Conduct road test if nec-
essary. After test, shut down the engine and do self-check (check if there are lost cotter pins,
washers and nuts etc). Make sure to check all hydraulic fluid levels again before operating the
machine.
2.4.22 Proper waste treatment
Improper disposal for waste may lead to envi-

ronmental and ecological perils. Consult your
local environmental collection center or Sany
Heavy Machinery Co., Ltd. authorized distrib-
utor about collection or disposal methods.
• Potential harmful waste from the equipment
of Sany Heavy Machinery Co., Ltd includes
hydraulic fluid, fuel, coolant, refrigerant, fil-
ter, battery and etc.
• Please store the drained liquid with a leak- CZ335-1102086
proof container instead of a food or drink Fig.2-95

container, as the latter may cause mistaken
drinking.
• Don’t pour waste liquid onto the ground, in-
to the sewer or any other water sources
directly.
• Leakage of refrigerant will damage the
earth atmosphere. Please recycle or regen-
erate the refrigerant according to relevant
laws and regulations.
CZ335-1102087
Fig.2-96


SY500H Hydraulic Excavator Technical Specifications
Technical Specifications
3 Technical Specifications.............................................................................................3-1
3.1 Overall dimensions ...............................................................................................................3-3
3.2 Working range .......................................................................................................................3-4
3.3 Technical parameters ...........................................................................................................3-5

Technical Specifications SY500H Hydraulic Excavator
WARNING

3.Technical Specifications
3.1 Overall dimensions
D I
E C
L
H
G F J
B K
CJ13032601-1
Fig.3-1
Unit: mm
Item SY500H
A Overall length (for transportation) 12095
B Overall width 3660
C Overall height (for transportation) 3775
D Width of upper structure 3290
E Overall height (top of the cab) 3470
F Standard track shoe width 600
G Track gauge 2740
Min. ground clearance(excluding the flange height of
H 560
the track shoe)
I Tail swing radius 3765
J Ground contact length of track 4410
K Track length 5440
Ground clearance of upper structure(excluding the
L 1350
flange height of the track shoe)

3.2 Working range
g
b
c d
CJ13032602-1
Fig.3-2
Unit: mm
Name SY500H
a Max. digging height 10950
b Max. dumping height 7450
c Max. digging depth 7490
d Max. vertical digging depth 5660
e Max. digging reach 11860
f Min. swing radius 5240
g Max. height at min. swing radius 9100

3.3 Technical parameters

Item Unit SY500H
Overall weight kg 35000
Bucket capacity m³ 1.6 (rock)
Engine model 6WG1XKSC-01
Engine power kW/rpm 300/1800
Traveling speed (high/low) km/h 5.5/3.5
Swing speed rpm 9.5


SY500H Hydraulic Excavator Operation
Operation
4 Operation.............................................................................................................................4-1
4.1 General drawing of machine................................................................................................4-5
4.2 Description of controls and instruments.............................................................................4-6
4.2.1 Display ..........................................................................................................................4-6
4.2.2 Switch ........................................................................................................................ 4-18
4.2.2.1 General............................................................................................................... 4-18
4.2.2.2 Ignition switch.................................................................................................... 4-18
4.2.2.3 Throttle control knob......................................................................................... 4-20
4.2.2.4 Working lamp switch ........................................................................................ 4-20
4.2.2.5 Ceiling lamp switch........................................................................................... 4-21
4.2.2.6 Wiper switch ...................................................................................................... 4-22
4.2.2.7 Washer switch ................................................................................................... 4-22
4.2.2.8 Horn switch ........................................................................................................ 4-23
4.2.2.9 Indoor lamp switch............................................................................................ 4-23
4.2.2.10 Cigar lighter and auxiliary power supply ..................................................... 4-24
4.2.2.11 Fault indicator lamp ........................................................................................ 4-24
4.2.2.12 Charging indicator lamp................................................................................. 4-24
4.2.2.13 Refueling pump switch................................................................................... 4-25
4.2.2.14 Alarm lamp (optional)..................................................................................... 4-25
4.2.2.15 Camera (optional)........................................................................................... 4-26
4.2.2.16 Emergency stop switch.................................................................................. 4-26
4.2.3 Control lever and pedal ........................................................................................... 4-27
4.2.3.1 General............................................................................................................... 4-27
4.2.3.2 Safety lock control lever................................................................................... 4-28
4.2.3.3 Traveling control mechanism .......................................................................... 4-29
4.2.3.4 Control levers .................................................................................................... 4-30
4.2.4 Roof............................................................................................................................ 4-31
4.2.5 Windshield................................................................................................................. 4-32
4.2.6 Doors and windows of cab...................................................................................... 4-39
Operation SY500H Hydraulic Excavator
4.2.7 Cup holder................................................................................................................. 4-40

4.2.8 Ashtray....................................................................................................................... 4-40
4.2.9 Information pack....................................................................................................... 4-41
4.2.10 Drink box ................................................................................................................. 4-41
4.2.11 Emergency exit....................................................................................................... 4-42
4.2.12 Fire Extinguisher .................................................................................................... 4-43
4.2.13 Controller................................................................................................................. 4-43
4.2.14 Fuse link .................................................................................................................. 4-44
4.2.15 Integrated fuse box ................................................................................................ 4-45
4.2.16 HVAC group ............................................................................................................ 4-46
4.2.16.1 Control panel ................................................................................................... 4-46
4.2.16.2 Control switch and LCD ................................................................................. 4-47
4.2.16.3 Operation of HVAC ......................................................................................... 4-52
4.2.16.4 Use HVAC carefully........................................................................................ 4-55
4.2.17 Radio........................................................................................................................ 4-57
4.2.17.1 Control panel ................................................................................................... 4-57
4.2.17.2 Control key and LCD...................................................................................... 4-57
4.2.17.3 Radio operation............................................................................................... 4-59
4.2.18 Door lock ................................................................................................................. 4-62
4.2.19 Lock cap .................................................................................................................. 4-62
4.2.19.1 General ............................................................................................................ 4-62
4.2.19.2 Open and close the lock cap......................................................................... 4-63
4.2.19.3 Open and close the lock cover ..................................................................... 4-64
4.2.20 Tool box ................................................................................................................... 4-65
4.2.21 Lubricating grease pump rack (if assembled).................................................... 4-65
4.3 Operation and control of machine.................................................................................... 4-65
4.3.1 Before engine start................................................................................................... 4-65
4.3.1.1 Routing inspection ............................................................................................ 4-65
4.3.1.2 Inspection before start...................................................................................... 4-67
4.3.1.3 Adjustment before operation........................................................................... 4-74
4.3.1.4 Operation before engine start ......................................................................... 4-78
4.3.2 Engine start ............................................................................................................... 4-80
4.3.3 Engine preheating.................................................................................................... 4-82
4.3.4 Warm-up operation .................................................................................................. 4-83
4.3.5 Stop the engine ........................................................................................................ 4-84
4.3.6 Machine operation ................................................................................................... 4-84
4.3.6.1 General............................................................................................................... 4-84
4.3.6.2 Preparation of moving machine...................................................................... 4-85
4.3.6.3 Move machine ................................................................................................... 4-86
4.3.6.4 Stop machine..................................................................................................... 4-87
4.3.7 Machine steering...................................................................................................... 4-88
4.3.7.1 General............................................................................................................... 4-88

4.3.7.2 Turn the machine when it stops ...................................................................... 4-88
4.3.7.3 In-situ steering................................................................................................... 4-90
4.3.8 Control and operation of work equipment............................................................. 4-90
4.3.9 Prohibited operation................................................................................................. 4-92
4.3.10 Allowed water depth .............................................................................................. 4-96
4.3.11 Operation on the slope .......................................................................................... 4-96
4.3.11.1 General............................................................................................................. 4-96
4.3.11.2 Downhill traveling............................................................................................ 4-98
4.3.11.3 Engine flameout on the slope........................................................................ 4-98
4.3.11.4 Cab door on the slope .................................................................................... 4-98
4.3.12 Drive the machine out of the mud........................................................................ 4-99
4.3.12.1 General ............................................................................................................ 4-99
4.3.12.2 Track on one side gets stuck in the mud ..................................................... 4-99
4.3.12.3 Tracks on both sides get stuck in the mud.................................................. 4-99
4.3.13 Recommended purpose ..................................................................................... 4-100
4.3.13.1 General .......................................................................................................... 4-100
4.3.13.2 Backhoe operation ....................................................................................... 4-100
4.3.13.3 Ditching work................................................................................................. 4-101
4.3.13.4 Loading operation......................................................................................... 4-101
4.3.14 Parking .................................................................................................................. 4-102
4.3.15 Machine inspection after daily work .................................................................. 4-104
4.3.16 Locking .................................................................................................................. 4-105
4.3.17 Operation in cold season .................................................................................... 4-105
4.3.17.1 Description of operation in cold weather ................................................... 4-105
4.3.17.2 After daily work.............................................................................................. 4-106
4.3.17.3 After the cold season ................................................................................... 4-107
4.3.18 Long-term storage ............................................................................................... 4-108
4.3.18.1 Before storage............................................................................................... 4-108
4.3.18.2 During storage............................................................................................... 4-108
4.3.18.3 After storage.................................................................................................. 4-109
4.3.18.4 Start the engine after long-term storage ................................................... 4-109
4.4 Transportation....................................................................................................................4-110
4.4.1 General .....................................................................................................................4-110
4.4.2 Transportation method ...........................................................................................4-110
4.4.3 Machine loading and unloading machine with trailer .........................................4-111
4.4.3.1 General..............................................................................................................4-111
4.4.3.2 Loading..............................................................................................................4-112
4.4.3.3 Secure the machine.........................................................................................4-114
4.4.3.4 Unloading..........................................................................................................4-117
4.5 Lifting...................................................................................................................................4-119
WARNING

4.Operation
4.1 General drawing of machine
Fig.4-1
[1] Bucket [6] Boom cylinder

[2] Bucket cylinder [7] Sprocket
[3] Arm [8] Track frame
[4] Arm cylinder [9] Shoe
[5] Boom [10] Idler

4.2 Description of controls and instruments

4.2.1 Display
CAUTION
• When the alarm indicator lamp comes on,
stop the operation immediately and check A
SANY
and repair relevant parts.
• The display can’t display the whole work-
ing status of the machine.
• Do not rely on the display completely in
case of maintenance and inspection of the B
machine.
The display panel has the functions of moni-

toring display, video selection and switching of
electric components.
Display appearance
C F1 F2 F3 F4 F5
The display is mainly composed of 3 parts:

15041401
A: SANY LOG display area
Fig.4-2
B: Main interface display area
C: Key area
SANY LOG display area
SANY LOG is shown in this area
SANY
15041402
Fig.4-3

Main interface display area 3

1 4
Skip to the main interface 3 s after entering 2 5
the LOG interface after power on. The full
screen display of the main interface of the dis- 6
play during the working status is as shown in
the Figure. Where: 7
8
9 12
10 11
1. System time
2. Working mode (divided by gear) 13 14 15 16 17 15041403
3. GPS signal Fig.4-4
4. Gear (according to the throttle knob

position)
5. Total working time
6. Fuel level gauge
7. Locking mark (locking countdown reminder)
8. Maintenance mark and maintenance time
9. Instantaneous fuel flow
10.Single working time
11.Cooling water thermometer
12.Display area of fault alarm mark and im-

portant fault icon
13.Enter the “Video Interface”
14.Automatic idle speed status
15.High/low speed traveling status
16.Icon of entering the “Fault Information

Query”
17.Icon of entering the “Information Query”

Key area
The button area includes 5 function buttons.
Function buttons:
Function buttons are F1, F2, F3, F4, and F5

(as shown) with purposes corresponding to
the function icons displayed on the main inter-
face display area above them.
When different function icons are displayed,

each button will have a different purpose. Fig.4-5
When no corresponding function icon is dis-
played in the main interface display area, this
function button will be invalid.
The corresponding relationship between com-

mon function icons and buttons is shown in
the figure.
LOG interface
SANY LOG is shown in this area
When the excavator ignition switch is turned

to "ON", the display will be powered and
started by the battery to enter the initial
interface.
15041405
Fig.4-6
Video interface
[F3] Full/split screen switching
Fig.4-7

Information list password interface
Select the “Running Information” in the “Infor-

mation List” interface, and press down F3 to
enter the information list password entry inter-
face (enter the password only for the first time
entry after power on each time). Run the infor-
mation query only after the password passes
verification.
Fig.4-8
Information list interface
Press F5 in the main interface to enter the In-

formation List interface, in which the informa-
tion to be queried can be selected.
Fig.4-9
System unlocking interface
Key operation
• [F1] Add and subtract the password
• [F2] Select the input digit
• [F3] Confirm the password
• [F4] —
• [F5] Return
Fig.4-10

Engine and throttle signal
Select the [Operation Information] in the [In-

formation List] interface to enter the operation
information query interface. The [Engine and
Throttle Signal] interface will be entered first.
Key operation
• [F1] Enter the [Input/Output Signal Query]
interface
• [F2] Enter the [Pilot Pressure Signal]
interface Fig.4-11
Pilot pressure signal
Press F2 in the [Engine and Throttle Signal]

interface, or press F1 in the [Main Pump and
Cooling Pump Signal] interface to enter the
[Pilot Pressure Signal] interface.
Key operation
• [F1] Enter the [Engine and Throttle Signal]
interface
• [F2] Enter the [Main Pump and Cooling
Pump Signal] interface
Fig.4-12
Main pump and cooling pump signal
Press F2 in the [Pilot Pressure Signal] inter-

face or press F1 in the [Input/Output Signal
Query] interface to enter the [Main Pump and
Cooling Pump Signal] interface.
Key operation
• [F1] Enter the [Pilot Pressure Signal]
interface
• [F2] Enter the [Input/Output Signal Query]
interface
Fig.4-13

Input/output switching signal query
Press F2 in the [Main Pump and Cooling

Pump Signal] interface or press F1 in the [En-
gine and Throttle Signal] interface to enter the
[Input/Output Signal Query] interface.
Key operation
• [F1] Enter the [Main Pump and Cooling
Pump Signal] interface
• [F2] Enter the [Engine and Throttle Signal]
interface Fig.4-14
Fault information
Select the [Fault Information] in the [Informa-

tion List] interface to query the fault code and
fault information.
Key operation
• [F1] Return to the previous page
• [F2]　－
• [F3]　－
• [F4]　－
• [F5] Return to the [Information List] Fig.4-15
interface
GPS monitoring information
Select the [GPS Monitoring] in the [Informa-

tion List] interface to query the GPS monitor-
ing information.
Key operation
• [F1]　－
• [F2]　－
• [F3]　－
• [F4]　－
• [F5] Return to the main interface Fig.4-16

System Language Selection
Select the [System Language] in the [Informa-

tion List] interface to enter the system lan-
guage selection interface, and Chinese and
English are available currently.
Key operation
• [F1]　－
• [F2] Chinese
• [F3] English
• [F4]　－ Fig.4-17
• [F5] Return to the [Information List]
interface
System Clock Calibration
Select the [System Clock] in the [Information

List] interface to enter the [System Clock Cali-
bration] interface
Key operation
• [F1] Add and subtract the setting value
• [F2] Select the setting bit
• [F3] Confirm the setting
• [F4]　－
interface
Maintenance information
Select the [Maintenance Information] in the

[Information List] interface to enter the mainte-
nance information query interface. The main-
tenance information includes maintenance
items for every 50 h, 250 h, 500 h, 1,000 h
and 2,000 h.
It can be accessed only when there is a main-

tenance reminder.
Key operation Fig.4-19

• [F1]　－
• [F2]　－
• [F3] Enter the Maintenance Password
interface

• [F4] Pause and start loop playback of the

maintenance item
interface
Maintenance confirmation
Press F3 in the [Maintenance Information] in-

terface to enter the Maintenance Password in-
terface, and input the maintenance password
for maintenance confirmation.
Key operation
• [F1] Add and subtract the password value
• [F2] Select the password digit
• [F3] Confirm the maintenance
• [F4]　－ Fig.4-20
interface
System Setting
Press down the F4 in the [Information List] in-

terface to enter the [System Setting] interface.
Enter the system setting interface to enter the
[System Setting] interface, and the password
entry mode is the same as the [Information
List Password Interface].
Key operation
• [F1] Select
• [F2]　－
Fig.4-21
• [F3] Confirm
• [F4]　－
interface

Machine configuration
Select the [Machine Configuration] in the

[System Setting] interface to query the ma-
chine configuration information.
Key operation
• [F1]　－
• [F2]　－
• [F3]　－
• [F4]　－
• [F5] Return to the [System Setting] interface Fig.4-22
Machine configuration calibration
Select the [Configuration Calibration] in the

[System Setting] interface to calibrate the ma-
chine configuration information. Enter the con-
figuration calibration password to enter the
[Configuration Calibration] interface, and the
password entry mode is the same as the [In-
formation List Password Interface].
Key operation
• [F1] Enter the [Machine Code Setting]
Fig.4-23
interface
• [F2] Calibrate the engine
• [F3] Confirm calibration and return to the
setting interface
• [F4] Set the hydraulic model
• [F5] Set the controller model
Working time calibration
Select the [Working Time] in the [System Set-

ting] interface to calibrate the working time of
the machine. Enter the working time calibra-
tion password to enter the [Working Time Cali-
bration] interface, and the password entry
mode is the same as the [Information List
Password Interface].
Note: The working time can be modified

twice, and it is unable to enter the subpage for
Fig.4-24
calibration when the remaining number is 0.

Key operation
• [F1] Add and subtract the setting value
• [F2] Select the setting bit
• [F3] Confirm
• [F4]　－
• [F5] Return to the [System Setting] interface
Alarm content setting
Select the [Alarm Content] in the [System Set-

ting] interface to enter the [Alarm Content Set-
ting] interface.
Key operation
• [F1] Select setting items
• [F2]　－
• [F3] Confirm the selected setting items
• [F4]　－
• [F5] Return to the [System Setting] interface Fig.4-25
Display brightness adjustment
Select the [Display Brightness] in the [System

Setting] interface to enter the [Display Bright-
ness Adjustment] interface.
Key operation
• [F1] Increase the brightness
• [F2] Reduce the brightness
• [F3] Confirm the brightness adjustment
• [F4]　－
interface

Traveling off-tracking setting
The system will set the level II password for

entry.
Key operation
• [F1] Select setting items
• [F2] Add value
• [F3] Subtract value
• [F4] Confirm
• [F5] Return to the [System Setting] interface
Fig.4-27
Engine information
Display the historical fault and total running

time of the engine.
Key operation
• [F1] Display the historical fault and total run-
ning time selection
• [F2] Enter the engine fault query page
• [F3] Confirm sending of requests
• [F4] Enter the other engine information
page Fig.4-28
• [F5] Return to the Setting Selection
interface
Engine fault information
Display the engine fault information.
Key operation
• [F1] Enter the next page
• [F2] —
• [F3] —
• [F4] —
• [F5] Return to the engine information
interface
Fig.4-29

Other information of engine
Display relevant information of engine.
Key operation
• [F1] Enter the Engine Basic Information in-
terface 4
• [F2] Enter the Engine Basic Information in-
terface 2
• [F3] —
• [F4] —
• [F5] Return to the engine information Fig.4-30
interface
Daily maintenance information
It will be popped up automatically upon the

first start every day.
Key operation
• [F1]　－
• [F2]　－
• [F3]　－
• [F4]　－
• [F5] Return to the main interface
Fig.4-31
Locking information
When the locking signal is received, enter the

locking information interface, and the locking
signal can be divided into the grade I locking
signal and the grade II locking signal.
Key operation
• [F1]　－
• [F2]　－
• [F3]　－
• [F4]　－ Fig.4-32
• [F5] Enter the Password Unlocking
interface

4.2.2 Switch
4.2.2.1 General
2
11 10
OFF ON
STA
3
AT
RT
HE
MAX
4
MIN
5
6
24V
9
14111908
Fig.4-33
[1] Ignition switch [7] Horn switch

[2] Throttle control knob [8] Indoor lamp switch
[3] Working lamp switch [9] Cigar lighter
[4] Wiper switch [10] Fault indicator lamp (red)
[5] Washer switch [11] Charging indicator lamp (yellow)
[6] Ceiling lamp switch
4.2.2.2 Ignition switch
The ignition switch is used to turn on or turn

off the engine. The ignition switch has four po-
sitions: HEAT, OFF, ON and START.

OFF position
The key can be inserted or removed. Both the

F
switches of the electric system (except the AT OF ON
HE
outdoor lamp) and the engine are turned off.
START
ON position
The current will flow through the charging and

lighting circuits. When the engine is running,
the ignition switch key will remain in this CC13031503
position.
Fig.4-34
START position
This is the engine start position. The key will

remain in this position upon start. Immediately
release the key after the engine start. It will
automatically return to the [ON] position.
HEAT position
This is the engine warm-up position. Insert the

key, then anticlockwise turn it to the [HEAT]
position and keep it at the position to warm up
the engine. After released, the key will auto-
matically return to the [OFF] position to stop
the warm-up.
NOTE：
For the machine equipped with glow plug
switch, the engine warm-up method may be
different. The [HEAT] position of ignition
switch for some models is invalid.

4.2.2.3 Throttle control knob
The throttle knob can be used adjust the en-

gine speed and output power. Rotate it clock-
wise to increase the engine speed, and rotate MA
it counterclockwise to reduce the engine X
speed.
MIN
Leftmost position [MIN]: Low idle speed
Rightmost position [MAX]: Full speed
CC13031401
Fig.4-35
4.2.2.4 Working lamp switch
The working lamp switch is used to turn on

and turn off the boom working lamp and the
platform working lamp.
CC13040203
Fig.4-36
Working lamp position
a.Boom working lamp―2
CZ335-1103040
Fig.4-37

b.Right platform working lamp―1
CZ335-1103041
Fig.4-38
4.2.2.5 Ceiling lamp switch
The ceiling lamp switch is used to turn on and

turn off the external ceiling lamp of cab.
CC13040204
Fig.4-39
Ceiling lamp position
CZ335-1103047
Fig.4-40

4.2.2.6 Wiper switch
CAUTION
• When using the wiper, please press down
the washer switch to spray a certain
amount of detergent to prevent friction and
damage of the wiper.
If the wiper shall be turned on when it is rain-

ing or the front windshield is dirty, press the
wiper switch, after which the wiper will work.
CC13040205
Fig.4-41
Fig.4-42
4.2.2.7 Washer switch
CAUTION
• Before pressing down the switch, it is nec-
essary to confirm that the front windshield
of the cab is closed.
Press down the washer switch to spray the

detergent. Press down and hold this switch,
and the detergent will be sprayed
continuously;
CC13040206
After release, the switch will bounce back au-
tomatically and the detergent will not be Fig.4-43
sprayed anymore.

4.2.2.8 Horn switch
The horn switch is installed on the top of the

right control lever, which is used to sound the
horn.
Press down and hold the switch, and the horn

will sound continuously.
CC13040209
Fig.4-44
4.2.2.9 Indoor lamp switch
The indoor lamp is installed inside the cab,

and the indoor lamp switch can be pressed
down to “Turn On” or “Turn Off” the indoor
lamp of cab.
Position [a]: The lamp is turned on
Position [b]: The lamp is turned off
NOTE：
Even though the ignition switch is in the OFF
position, the indoor lamp can be turned on.
Fig.4-45

4.2.2.10 Cigar lighter and auxiliary power supply
Use a cigar lighter when lighting a cigarette.

When a cigar lighter is pushed in, it will return
to its original position a few seconds later, and
it can be used after removal.
If the cigar lighter is removed, its socket can

be used as the power supply not higher than 24V
240 W (24 V×10 A).
NOTE：
This cigar lighter is 24 V, and it can’t be used CC13041502
as the power supply of 12 V equipment.

Fig.4-46
4.2.2.11 Fault indicator lamp
The fault indicator lamp [1] comes on when

the engine is faulty. The indicator lamp goes
out after the fault is eliminated. In case of any
fault, please handle the fault timely, and con-
X
START
MA
T OFF ON
duct operation only after the fault is

HEA
eliminated. NIM
1 2
CC13040211-1
Fig.4-47
4.2.2.12 Charging indicator lamp
The charging indicator lamp [2] comes on

when the ignition switch is at ON position; the
indicator lamp goes out when the engine is
running and the alternator works normally; if
the indicator lamp stays on, check if the alter-
nator is faulty.

4.2.2.13 Refueling pump switch
This switch is located in the toolbox on the

right of the platform.
When refueling the machine, adjust the ball

valve horizontal, lift the red cover of the refuel-
ing pump switch, and push the switch up.
Then the refueling pump works; after refuel-
ing, lower down the red cover of the refueling
pump switch, after which the refueling stops.
After that, turn the ball valve to the illustrated
position.
Fig.4-48
Fig.4-49
4.2.2.14 Alarm lamp (optional)
The alarm lamp is an optional configuration,

located as shown in the figure. The alarm con-
tent is set via the display.
Fig.4-50

4.2.2.15 Camera (optional)
The camera is an optional configuration, lo-

cated as shown in the figure. The camera is
turned on or off via the display.
14112029
Fig.4-51
4.2.2.16 Emergency stop switch
1. The emergency stop switch is located under

the cab seat, and it is used to stop the engine
in case of an emergency. In case of an emer-
gency, open the red cover, pull the switch up-
wards, and reset the switch after the engine is
stopped.
14112030
Fig.4-52

4.2.3 Control lever and pedal
4.2.3.1 General
2
4
CC13040210-1
Fig.4-53
[1] Safety lock control lever [3] Traveling control mechanism

[2] Left control lever [4] Right control lever

4.2.3.2 Safety lock control lever
WARNING
• When leaving the cab, the safety lock con-
trol lever shall be firmly located at the lock-
ing position. If the safety lock control lever
is not at the “LOCK” position, accidental
touching of the joystick can cause serious
casualties.
• If the safety lock control lever is not at the
“LOCK” position, the joystick may move,
thus causing serious accidents. The in-
spection of the joystick is as shown in the
figure.
• When pulling or pushing the safety lock
control lever, do not touch the left control
lever.
A safety lock control lever is a device that

locks the work equipment, swing, travel and
accessory (if equipped) control levers.
• LOCK position: Push the safety lock con-
trol lever downwards and apply the locking.
The machine will not move even if the con-
trol lever is operated.
• UNLOCK position: The machine will move
according to operation of the joystick.
CC13031504
The lever is a hydraulic locking lever. There-
Fig.4-54
fore, when it is locked, the joystick or the con-
trol pedal will move, but the machine will not
move.
When all the controllers are in the neutral po-

sition and the safety lock control lever is
pushed to the unlocking position, if any part of
the machine (has movement tendency)
moves, it indicates that the machine has fault.
In this case, immediately pull the safety lock
control lever back to the LOCK position and
CC13030402
stop the engine. And then contact SANY
Heavy Machinery or its authorized agent. Fig.4-55

4.2.3.3 Traveling control mechanism
WARNING
• Do not put your feet on the pedal while op-
erating. If the pedal is stepped down acci-
dentally, the machine will suddenly move
and cause a serious accident.
• Please be cautious when using a pedal for
traveling or steering. Do not put your feet
on the pedal when you do not use the
pedal.
The travel lever and traveling control pedal

a
(as shown in the right Figure) are used to con-
trol machine traveling and change traveling di- N
rection of the machine. a
[a] Forward: b
N
Push the travel lever forwards (or step down

front part of pedal) b a
a
[b] Reverse: b
Pull the travel lever backwards (or step down b
rear part of pedal)
[N] Stop the machine (return the travel lever

CZ335-1103054
and pedal to the neutral position)
Fig.4-56
NOTE：
Confirm the sprocket position before operat-
ing the travel lever or pedal. Ensure that the
sprocket is at the back of the machine. If the
sprocket is in front of the machine and the
travel lever is pushed forwards, the machine
will move backwards.

4.2.3.4 Control levers
WARNING
• Do not extend any part of your body out of
the window. If you knock into the boom
control lever accidentally or for other rea-
sons, you may be hit by the boom. If the
window is lost or damaged, it shall be re-
paired or replaced immediately.
• Before operation, be familiar with the posi-
tion and function of each control lever to
prevent injury caused by accidental move-
ment of the machine.
The following is an example of the SAE mode.

For details, see the “Work Equipment Control
and Operation” on page 4-84.
Left control lever

Action of the left control lever
3
1 Front Arm dumping 1
2 Back Arm digging
2
3 Left Left swing 4
4 Right Right swing
• The diagonal movement of the control lever

can realize two functions and can perform
compound action. CC13031505
Fig.4-57
3 4
CZ335-1103056
Fig.4-58

Right control lever

Action of the right control lever 8
5
5 Front Boom lowering
6
6 Back Boom lifting 7
7 Left Bucket digging
8 Right Bucket dumping
• The diagonal movement of the control lever

can realize two functions and can perform CC13031506
compound action.
Fig.4-59
NOTE：
• When the travel levers and the joysticks are
at neutral position, as long as the accelerator
rotary switch is at the position for a speed 5
higher than the auto idle speed, operating ei-
7 8
ther control lever will increase the engine
speed to the speed set by the accelerator ro-
6
tary switch.
• If the travel lever and control lever are in the
neutral position, the engine speed will drop
CZ335-1103058
automatically to the set speed (about 1,100
rpm) after about 3.5 s. Fig.4-60
• When the travel lever and the control lever
are released, it will automatically return to
the neutral position and the machine function
will be disabled.
4.2.4 Roof
WARNING
• When leaving the driver’s seat, the safety
lock control lever shall be firmly located at
the locking position. If the safety lock con-
trol lever is in the unlocking position, acci-
dental touching of the travel lever or pedal
can cause serious accident.
ON

1. Turn the safety lock control lever to the

“LOCK” position.
CC13031403
Fig.4-61
2. Push the lock [B] on both sides of the roof

handle [A] upwards, and then hold the handle
[A] and push the roof upwards. B B
CZ335-1103060
Fig.4-62
OFF
Hold the handle [A] to pull the roof down-

wards, and the lock [B] will be automatically
applied. If the lock can't be properly engaged,
open the roof and try to lock it.
4.2.5 Windshield
• The front windshield can be retracted

(pulled) to the top of the cab.
• Before opening or closing the front wind-
shield, stop the machine on the level
ground, completely drop the work equip-
ment to the ground, stop the engine, and
then operate it.
• When opening the front windshield, hold
the handle and pull it upwards with both
hands, and do not loosen hands until the

automatic latch bolt is locked.
• When the front windshield is closed, the
window will move quickly under its own
deadweight. When it is closed, hold the
handle with both hands.
WARNING
• Turn the safety lock control lever to the
locking position when the front windshield,
bottom window or door are opened or
closed.
• If the safety lock control lever is in the un-
locking position, accidental touching of the
travel lever or control pedal can cause seri-
ous accident.
ON
1. Stop the machine on the level ground, com-

pletely drop the work equipment to the
ground, and then stop the engine.

CC13031403
Fig.4-63
3. Check the wiper blade and place it in the

right support.
CZ335-1103062
Fig.4-64

4. Hold the left and right handle [A] on the top

of the front windshield and pull two handles
[B] to release the lock on the top of the front
windshield. The top of the front windshield will
be released.
A A
CZ335-1103063
Fig.4-65
B
A
CZ335-1103064
Fig.4-66

5. Hold the bottom handle [C] with left hand

and hold the top handle [D] with right hand in
the cab, and pull it upwards. In addition, push
the latch bolt [E] towards the back of the cab D
to firmly lock the front windshield.
CZ335-1103065
Fig.4-67
CZ335-1103067
Fig.4-68
CZ335-1103066
Fig.4-69

6. Check whether the handle [B] in firmly lo-

cated in the “LOCK” position.
• Check whether the arrow on the lock shell
F
[F] is aligned with the arrow on the handle
[B], if yes, the lock will be engaged.
• If the arrow on the lock shell [F] is not
aligned with the arrow on the handle [B], B
the lock will not be engaged. Please repeat
operations in the step 5 to engage the lock.
CZ335-1103068
Fig.4-70
OFF
CAUTION
• When closing the front windshield, slowly
lower it down and be careful not to get
stuck.
1. Stop the machine on the level ground, com-

pletely drop the work equipment to the
ground, and then stop the engine.

CC13031403
Fig.4-71

3. Hold the left and right handle [A] and pull

the handle [B] downwards to release the lock.
CZ335-1103069
Fig.4-72
4. Hold the handle [C] at the bottom of the

front windshield with left hand, hold the handle
[D] on the top of the front windshield with right
hand, push it forwards, and then slowly lower
it down.
Fig.4-73
CZ135B-1103009
Fig.4-74

5. When the bottom of the front windshield

reaches the top of the bottom window, push
G
the top of the front windshield forwards to
push it to the left and right latch bolt [G] and
engage the lock.
CZ335-1103072
Fig.4-75
6. Check whether the handle [B] in firmly lo-

cated in the “LOCK” position.
• Check whether the arrow on the lock shell
[F] is aligned with the arrow on the handle F
[B], if yes, the lock will be engaged.

• If the arrow on the lock shell [F] is not
aligned with the arrow on the handle [B],
B
the lock will not be engaged. Please repeat
operations in the step 5 to engage the lock.
CZ335-1103068
Fig.4-76
Remove the lower windshield
Open the front windshield, and then hold the

left and right handles and pull them upwards,
and remove the lower windshield.
CZ335-1103077
Fig.4-77

If the bottom of the front windshield has accu-

mulated sand or dust, it will be difficult to re-
move the front windshield. In addition, when
the front windshield is retracted, the sticky
sand and dust will be brought into the cab. To
prevent this condition, clean the [A] area be-
fore removal.
A
CZ335-1103078
Fig.4-78
4.2.6 Doors and windows of cab
ON
1. Press down the latch when opening the

window of the cab door.
2. Slide the front windshield backwards and

(or) slide the rear window forwards.
OFF
1. Slide the front windshield forwards and (or)

CZ335-1103079
slide the rear window backwards.
Fig.4-79
2. Close the doors and windows and ensure
that the latch is completely locked.

4.2.7 Cup holder
There is a cup holder in the cab to facilitate

the driver to place cup (kettle).
0-13004
Fig.4-80
4.2.8 Ashtray
• This ashtray is on the left of the cup holder.

• When cigarette is put in the ashtray, it shall
be put out. Close the ashtray when it is
placed in.
0-13007
Fig.4-81

4.2.9 Information pack
• The information pack is located on the back

of the driver’s seat back. The right Figure is
the effect when the seat back is completely
lowered down.
• The “Operation and Maintenance Manual”
is placed in this pack, which can be read
when necessary.
CZ335-1103090
Fig.4-82
4.2.10 Drink box
• The drink box is located on the left side of

the back of the driver’s seat. It can keep the
beverage warm and cool in the winter and
summer.
• It can blow hot or cool air to the drink box
according to the setting of HVAC.
0-13005
Fig.4-83

4.2.11 Emergency exit
If the door and window of the cab can't be

opened in case of emergency, the rear win-
dow can be used as an emergency exit.
• For a cab with a safety hammer, the safety
hammer can be used to break the rear win-
dow. The safety hammer is located on the
left side of the rear window of the cab.
CZ215-1103029
Fig.4-84
• For the pull ring rear window, pull the pull

ring, remove the rubber core from the win-
dow frame rubber, and then forcibly push
the glass corner to remove the glass from
the window.
NOTE：
The rear window can be used as an escape
exit only in case of emergency. Do not use it
at any time.
Fig.4-85

4.2.12 Fire Extinguisher
CAUTION
• Be sure to prepare a fire extinguisher and
read the label, and be familiar with the op-
eration method in case of emergency.
• Regularly check the fire extinguisher and
ensure that it is in the warranty period.
• If the fire extinguisher has expired, it shall
be replaced timely.
The fire extinguisher shall be kept in the rear

CZ215-1103044
part of the cab.
Fig.4-86
4.2.13 Controller
Be careful not to get water, mud or other liquid

onto the controller. This will cause a fault.
If the controller has any fault, please do not

disassemble it without permission, and con-
tact the authorized agent of SANY Heavy Ma-
chinery for repair.
CB13041001-1
Fig.4-87

4.2.14 Fuse link
When the ignition switch is turned to the [ON]

position, if the starting motor can't be started,
the fuse link may have an open circuit. The
fuse box is located in the electrical control box
at the back of the cab. Check for fuse burnout,
and replace the fuse if necessary.
NOTE：
• The fuse link (as shown in the Figure) refers
to the fuse installed on the circuit to prevent CC13032901
burning electric parts and wires.

Fig.4-88
• The fuse link has specifications including 5
A, 10 A, 15 A, 20 A and 30 A, which is distin-
guished with different colors. Replace the old
fuse link with the one with the same capacity.
• Always turn off the ignition switch before re-
placing the fuse link.

4.2.15 Integrated fuse box
Integrated fuse box

Fuse/ relay No. Rating system
F1 20A Start circuit
F2 15A Power-on signal
F3 10A Starting signal
F4 5A Extinguishing delay
F5 10A Charging indicator
F6 20A Main controller power
F7 10A Display power supply
F8 15A Manual/automatic
F9 10A Radio
F10 5A Alarm lamp (sound)
F11 10A Fuel filter pump
F12 10A Cigar lighter
F13 10A +24V power supply
F14 20A Work light
F15 20A Cab ceiling lamp
F16 5A Alarm lamp (sound
F17 5A Wiper/washer
F18 20A A/C
F19 5A GPS power
F20 30A ECM power
F21 15A PVC power
F22 10A Electromagnetic pump
F23 15A Horn
F24 5A Indoor lamp
F25 5A Access lamp
F26 10A Refueling pump
F27 10A Reserved
F28 30A Reserved
K2 24V,20A 5-PIN MICRO Main controller power relay
K3 24V,20A 5-PIN MICRO Work lamp relay
K4 24V,20A 5-PIN MICRO Cab ceiling lamp relay

Integrated fuse box

Fuse/ relay No. Rating system
K5 24V,20A 5-PIN MICRO Alarm lamp (buzzer) relay
K8 24V,20A 5-PIN MICRO Electromagnetic pump relay
K9 24V,20A 5-PIN MICRO Horn relay
K10 24V,20A 5-PIN MICRO Fuel filter pump relay
K11 24V,20A 5-PIN MICRO Alarm lamp (light) relay
K12 24V,20A 5-PIN MICRO Shutdown delay relay
K15 24V,20A 5-PIN MICRO Refueling pump relay
K16 24V,20A 5-PIN MICRO Reserved
K17 24V,20A 5-PIN MICRO Reserved
4.2.16 HVAC group
4.2.16.1 Control panel
1 2 3 4 5
6 7 8
CZ205-1203020G
Fig.4-89
[1] OFF switch [5] Automatic mode setting switch

[2] Fan speed setting switch [6] Internal/external circulation selector switch
[3] Temperature setting switch [7] LCD
[4] Air vent mode setting switch [8] HVAC switch

4.2.16.2 Control switch and LCD
1. OFF switch
This switch can be used to turn off fan and

HVAC.
Press down the OFF switch [1], and indication

of the setting temperature and air volume of OFF
the LCD will disappear, the upper lamp of the
automatic mode switch [5] and the HVAC
switch [8] will be off, and running will be CZ335-1103094
stopped.
Fig.4-90
2. Fan speed setting switch
This switch is used to adjust the air volume

and can set the air volume to six levels from
weak to strong. The air volume will be dis-
played on the LCD.
• Press down the switch to increase the air
volume.
• Press down the switch to reduce the air
volume.
• The air volume will be automatically Fig.4-91
switched during operation under the auto-
matic mode.
LCD display and air volume
LCD Air volume
Weak
Medium 1
Medium 2
Medium 3
Medium 4
Strong

3. Temperature setting switch
This switch is used to set the cab tempera-

ture. Temperature setting range: 18~32° C
(64.4~89.6°F)
• Press down the switch to increase the
set temperature.
• Press down the switch to reduce the set
temperature.
• The operation temperature is generally 25°
Fig.4-92
C (77°F).
LCD display and function

LCD Set temperature
18.0°C Maximum refrigerating
Adjust the temperature to
18.5~31.5°C make the cab reach the
set temperature
32.0°C Maximum heating
4. Air vent mode setting switch
This switch can be used to select the air vent.

• Press down the switch [4], and the LCD dis-
play mode will be changed, and the air will
be supplied from the air vent under the dis- MODE
played mode.
• The air vent mode will be automatically
switched under the automatic operation CZ335-1103225
mode.
Fig.4-93

Description of air vent mode

Air vent
LCD Air vent Remarks
A B C D
It can't be selected under the
Front face air vent ○
automatic operation mode
Front/back face air
○ ○
vent
Front/back face and
○ ○ ○
foot air vent
Foot air vent ○
Foot and defrosting It can't be selected under the

○ ○
air vent automatic operation mode
It can't be selected under the
Defrosting air vent ○
automatic operation mode
NOTE：
Air will be supplied from the air vent marked
with ○.
Air vent of HVAC
[A]: Rear air vent: It is generally located at the

back of the cab.
Fig.4-94

[B]: Face air vent
[C]: Defroster port

F1 F2 F3 F4 F5
Esc
Enter
24V
C B
0-13011-1
Fig.4-95
[D]: Foot air vent: It is located below the cab.
NOTE：
• The appearance and quantity of air vent of
HVAC may vary slightly depending on ma-
chine model.
• The direction of the face air vent, defroster D
port and rear air vent can be adjusted, but

the foot air vent can’t be adjusted.
CZ335-1103100
Fig.4-96
5. Automatic mode setting switch
This switch is used to automatically set the air

volume, air vent and inside and outside air
switching according to the set temperature.
• Press down the automatic mode setting
switch [5], and the indicator lamp on the top
AUTO
of the switch will be on.
• Generally, press down this switch and set to
CZ335-1103101
the proper temperature with the tempera-
ture setting switch [3], and the HVAC will Fig.4-97
run automatically.
• When switching from automatic mode to
manual mode, just reset the air volume, air
vent and inside and outside air switching
mode with the switches. In this case, the

indicator lamp on the top of the switch will

be off.
NOTE：
When the automatic mode is selected, if the
temperature is set to 18℃ (64.4℉) or 32℃
(89.6℉) and the air flow always keeps at
HIGH, this is not a fault.
6. Internal/external circulation mode setting

switch
This switch is used to switch internal circula-

tion and external circulation.
• Press down one of the switches [6], and the
indicator lamp on the top of the switch will
be on.
• The external circulation mode and the inter- CZ335-1103102
nal circulation mode will be automatically
switched during operation under the auto- Fig.4-98
matic mode.
The external circulation is
closed, only the internal
Internal circulation mode is activated
circulation It is suitable for internal fast
cooling and heating or when
the external air is dirty
A mode the external air is
External introduced into the inside
circulation It is suitable for clean air
introduction and defogging
7. LCD
c
The LCD [7] is used to display the setting tem-
perature [a], air volume [b] and air vent status
[c] during running.
• Press down the OFF switch [1], and indica- a
tion of the setting temperature, air volume
and air vent status will disappear, and run- b
ning will be stopped.

CZ335-1103103
Fig.4-99

8. HVAC switch
This switch is used to control start and stop of

actions (refrigeration, dehumidification and
heating) of HVAC.
• When the fan is working ([b] is displayed on A/C
the LCD), press down the HVAC switch [8],
and the HVAC will be turned on and the in-
dicator lamp on the top of the switch will be CZ335-1103104
on; press it down again, the HVAC will be
Fig.4-100
turned off, and the indicator lamp will be off.
• When the fan is turned off (no air supply
status is displayed on the LCD), the HVAC
can’t be turned on.
4.2.16.3 Operation of HVAC
The HVAC can be controlled automatically or

manually. Select the control mode as
required.
Automatic operation
c
1. Turn on the automatic mode setting switch
AUTO
。
In this case, the temperature [a] and air vol-
ume [b] will be displayed on the LCD, and the a
lamp on the top of the automatic switch and AUTO
the HVAC switch will be on.

A/C b
2. Adjust the temperature switch , and set the

TEMP
CZ335-1103103
comfortable temperature.
Set the temperature accordingly, and the Fig.4-101
HVAC will automatically switch the air volume,
the air vent and the inside and outside air to
provide the set temperature.

NOTE：
When the air vent mode [c] displays [d] or [e]
d e
status and the engine coolant temperature is
lower, the air volume will be automatically re-
stricted to prevent blowing air cool air.
CZ335-1103107
Fig.4-102
Stop automatic operation
Press down the switch OFF

, and automatic op-
eration will be stopped.
Manual operation
c
1. Press down the fan speed setting switch to
adjust air volume. In this case, check the tem-
perature [a] and air volume [b] displayed on
a
the LCD.
b
2. Turn on the HVAC switch A/C
.
3. Press down the temperature adjustment CZ335-1103103
switch to set the cab temperature.

TEMP
Fig.4-103
4. Press down the air vent mode setting
switch MODE
to set the required mode. In this
case, the display of the [c] on the LCD will be
changed according to selections.
5. Press down the inside/outside air change-

over switch or , and select the cab inside
air circulation or outside air guidance mode.
Stop manual operation
Press down the switch, and manual opera-

OFF
tion will be stopped.

Bi-Level mode
To blow cool air to face and hot air to foot,

make setting with the following methods:
1. Press down the fan speed setting switch

to adjust air volume. In this case, check the
temperature [a] and air volume [b] displayed
on the LCD.
CZ335-1103226
2. Press down the air vent mode setting
switch MODE
, and display the air vent mode on Fig.4-104
the LCD as the status as shown in the right
Figure.
3. Turn on the HVAC switch A/C

.
4. Adjust the fan speed setting switch tem-

perature setting switch TEMP
and inside/outside
air mode setting switch or to the required
position.
Defrosting
1. Press down the fan switch to adjust air

volume. In this case, check the temperature c
[a] and air volume [b] displayed on the LCD.
CZ335-1103103
Fig.4-105

2. Press down the air vent mode setting switch

MODE
, and display the air vent mode on the LCD
as the [f] or [g] as shown in the right Figure. f g
3. Press down the inside/outside air change-

over switch or , and set it to the outside
air guidance mode.
4. Press down the temperature setting switch

, and set the temperature on the LCD to the
TEMP
CZ335-1103109
hottest (32℃).
Fig.4-106
• During operation in the rainy season or de-

fogging or dehumidification of the window,
turn on the HVAC switch A/C
for
dehumidification.
4.2.16.4 Use HVAC carefully
• When operating HVAC, be sure to start it

when the engine is running at low speed.
Do not turn on the HVAC when the engine
is running at high speed. Otherwise, it will
cause HVAC fault.
• If the water enters the control panel or the
daylight sensor, it will cause an accident
fault. Be careful not to get water on these
parts. In addition, do not make open fire
close to these parts.
CZ215-1103040
• For normal operation of automatic function
of the HVAC, be sure to keep the daylight Fig.4-107
sensor clean, and do not place anything
around the daylight sensor, otherwise it will
affect the function of the sensor.
Ventilation
• When the HVAC is running for a long time,
the “Inside and Outside Air Mode” shall be
changed to the “Outside Air Guidance”
mode every 1 h for ventilation.
• In case of smoking when the HVAC is
turned on, the smoke will hurt your eyes,

therefore, the “Inside and Outside Air Mode”

shall be changed to the “Outside Air Guid-
ance” mode to ensure that smoke can be
removed in continuous cooling.
Temperature control
• When the cooler works, set the temperature
to a value (5 or 6℃(9 or 10.8℉) lower than
outdoor temperature) slightly lower than
that when entering the cab. The tempera-
ture difference is considered to be the most
suitable for health.
Inspection and maintenance of machine

with HVAC
• The inspection and maintenance of ma-
chine with HVAC shall be carried out ac-
cording to charts. For details, see the
“Inspection and Maintenance of HVAC” on
page 5-27.
• When the HVAC is not used for a long time,
it is necessary to operate the engine at a
low speed to prevent the loss of the oil film
on each part, and perform refrigeration, de-
humidification and heating for a few
minutes.
• If the cab temperature is lower than the out-
door temperature, the HVAC will not work.
In this case, the circulation of fresh air will
heat up the cab, and the HVAC will work
when the HVAC switch is turned on again.
• If any device or sensor on the HVAC has
any fault, please contact the authorized
agent of SANY Heavy Machinery for in-
spection and repair.

4.2.17 Radio
4.2.17.1 Control panel
Fig.4-108
[1] Power switch key [6] Preset station key (1~6)

[2] Audio conversion key [7] LCD
[3] Time display key [8] Tuning key
[4] FM / AM conversion key [9] Volume adjustment key
[5] AS/PS key
4.2.17.2 Control key and LCD
[1] Power switch key
Press down the power switch to power on the radio. The frequency will be displayed on the dis-
play [7]. Press down this switch again to power it off.
[2] Audio conversion key
After pressing down the audio conversion key , the audio status will be displayed as follows:
SEL
VOL→BAS →TRE→BAL.
The host will return to the frequency display interface if there is no operation within 5 s.
The audio status will be displayed on the display [7].

[3] Time display key
Press down the time display key when the frequency is displayed, and the current time will be
TIME
displayed on the display for 5 s. The display will automatically recover to the frequency display 5 s
later.
If pressing down and holding the key [3] for more than 5 s, the national area: ASA: EU (Asia: Eu-
rope) will be displayed.
[4] FM / AM conversion key
Press down the FM/AM conversion key to select the required band. After this key is pressed
FM/AM
down each time, the band will be switched between FM→AM→FM.
[5] AS/PS (automatic search and preset station) key
The function of the AS/PS key is to: Automatically search and save the station and browse and
play the preset station. Automatically search and save the station:
In the radio status, press down the AS/PS key to scan each preset station in turn, and it will stop
AS/PS
at each preset station for 10 s, and the characters of the scanned preset position will flash on the
display. If you need to listen to a station, press down the again to stay at this station.
AS/PS
Browse and play the preset station:
In the radio status, press down the AS/PS key and wait for more than 2 s, and it will begin to au-
AS/PS
tomatically search the current band station, save 6 stations with the strongest signal in 1-6 memo-
ries in order, and finally lock the station and begin playing.
[6] Preset station key (PRESETSTATION)
If the preset station keys (1~6) are used to determine which stations are preset, you can select the
required station with the key.
[7] LCD
The receiving band, frequency, preset number and time will be displayed on the display.
[8] Tuning key (TUNING)
Press down the tuning key and to change frequency.
key: Move frequency downwards
key: Move frequency upwards

[9] Time adjustment key (TIMEADJ)
Press down the key in the keys to increase the volume in turn to 40.
Press down the key to reduce the volume in turn to 0.
It will return to the frequency display interface if there is no operation within 5 s.
4.2.17.3 Radio operation
Method of setting with preset key
1. Press down the power switch [1]. In this 2 7

case, the frequency will be displayed on the
ST
AM
display [7]. AS/PS AM/FM TIME SEL
FM
PRESET STATION TUNING VOL SANY
1 2 3 4 5 6 - +
2. Adjust it to the required frequency with the
upward and downward search key [8]. There
6 8 1
are two tuning methods including automatic
14112032
tuning and manual tuning.
Fig.4-109
3. When the required frequency is displayed
on the display [7], the received sound will dis-
appear after at least 1.5 s after the preset
number required is pressed down and held.
But when the preset operation (saving in
memory) is completed, the sound will appear
again, and the preset number and frequency
will be displayed on the display to indicate that
the preset operation has been completed.
When the preset is completed, press down
the radio preset station key [6] and release it
within 1.5 s, so as to receive the preset band
of the key.
NOTE：
The automatic storage key can be used to
save it to the preset key.
Station search method

1. Press down the power switch [1]. In this

case, the frequency will be displayed on the
display [7].
2. Adjust it to the required frequency with the

tuning key [8]. There are two tuning methods
including automatic tuning and manual tuning.
• Manual tuning
Press down the tuning key [8] until the fre-
quency is displayed on the display [7].
When the frequency reaches the top or bot-
tom frequency, it will automatically continue
in the order of top→bottom or bottom→top.
• Automatic tuning
Press down and hold the tuning key [8] to
automatically search the station up or down.
When a station is received, the tuning will
stop automatically. In order to search for the
next station, just press down and hold the
tuning key [8].
If this key is pressed down during the auto-
matic tuning, the automatic tuning will be
canceled. The setting will recover it to the
frequency used before this key is pressed
down.
Audio adjustment
• VOL adjustment (VOL): Press down the

key to increase the volume in turn to 40;
press down the key to reduce the volume
in turn to 0;
• BAS adjustment (BAS): Firstly press down
the key to switch the audio to the BAS
SEL
mode, and then press down the or key

within 5 s to change the BAS loudness with-
in the range of +7~-7.
• TRE adjustment (TRE): Firstly press down
the key to switch the audio to the TRE
SEL

within 5 s to change the TRE loudness with-
in the range of +7~-7.

• BAL adjustment (BAL): Firstly press down

the key to switch the audio to the BAL
SEL

within 5 s to change balance of the left and
right sound tracks within the range of L9-
R9. BAL.0 represents balance between left
and right sound tracks.
NOTE：
For all modes, if there is no operation within 5
s, the LED display will be automatically recov-
ered to the original setting.
Antenna
Before moving the machine to the inside of

the building, the antenna shall be retracted to
prevent any interference. Retract the antenna
as follows: 1
A
1. Loosen the mounting bolts of the antenna
[1], and place the antenna in the position [A].
2. After retracting the antenna, tighten the bolt

[1]. CZ335-1103114
Use the radio carefully Fig.4-110

• In order to ensure safety, the volume shall
be kept at the level where the external noise
can be heard during operation.
• If water flows into the loudspeaker box or
radio, it will cause an accident, so be careful
not to get the water on the device.
• Do not use benzene, diluent or other sol-
vent to wipe off the control panel or key.
Wipe it off with a piece of soft cloth. If the
device is too dirty, wipe it off with a piece of
cloth dipped with alcohol.
• When the battery is disconnected or re-
placed, the setting of the preset key and the
clock will be cleared, so all settings shall be
reset.

4.2.18 Door lock
CAUTION
• Stop the machine on the level ground before releasing the door lock.
• Do not release the door lock on the slope. The door may be closed suddenly and damaged.
• Do not extend your body or hand out of the door before you release the door lock. Do not put
your hand on the door frame. The door may be suddenly closed and damaged.
1. Push the cab door to the latch bolt [1] direc-

tion to lock it.
2. When closing the door, press down the han-

dle [2] on the left side of the driver’s seat to re-
lease the latch bolt [1]. 1
When the door is opened, lock the door firmly

2
to the latch bolt [1].
CZ335-1103082
Fig.4-111
4.2.19 Lock cap
4.2.19.1 General
Open/close lock on the cap and cover with the

ignition switch key.
For details of the lock cap and cover, see the

“Locking” on page 4-98.
Insert the key to the shoulder [A].
NOTE：
Turning the key when it is not inserted at the A
bottom may cause breakage.
CZ335-1103083
Fig.4-112

4.2.19.2 Open and close the lock cap
CAUTION
• After removing the key, be sure to rotate
the cap [1] to cover the keyhole. Other-
wise, foreign matters in the cap lock will
make the switch inflexible or even
disabled.
• When the lock cap is tightened, the stroke
is larger. Ensure that the lock cap is rotated
properly, and then turn the key to lock the
lock cap. If the key is removed when rota-
tion is not completed, the latch bolt will
touch on the inner wall of the filler to dam-
age the lock cylinder.
• It is necessary to ensure the cleanness of
the sealing ring in the lock cap. If the seal-
ing ring is stained with impurities including
iron chips and stones, it will be easily dam-
aged during tightening, causing improper
sealing of the lock cap.
Open the cap
1. Unscrew the keyhole cap [1].

1
2
2. Insert the key into the key slot.
3. Rotate the key clockwise to align the key

B
slot at the mark [A] on the cap, and then open
the cap [2]. A
Position [A]: Open

CZ215-1103001
Position [B]: Locked
Fig.4-113

Lock the cap
1. Tighten the cap [2] and insert the key into 1
the key slot.
2. Rotate the ignition switch key to the “LOCK”

position [B], and remove the key.
B
3. Rotate the cap [1] to cover the keyhole. A
CZ215-1103002
Fig.4-114
4.2.19.3 Open and close the lock cover
Open the cover (locked cover)
1. Insert the key into the key slot.

A
2. Rotate the key counterclockwise and open

the cover through its handle.
Position [A]: Open
Position [B]: Locked

B
Lock the cover
CZ335-1103085
1. Close the cover, and insert the key into the

Fig.4-115
key slot.
2. Rotate the key clockwise and remove it.

4.2.20 Tool box
It is used to store tools.
CZ205-1203022G
Fig.4-116
4.2.21 Lubricating grease pump rack (if assembled)
The lubricating grease pump rack is installed

in the access door at the left rear part of the
machine. Hook the lubricating grease pump
on this rack when it is not used.
CZ335S-1103048
Fig.4-117
4.3 Operation and control of machine

4.3.1 Before engine start
4.3.1.1 Routing inspection
Before starting the engine, check the machine and the part below it. Check whether bolts or nuts
are loose, whether there is oil, fuel or coolant leakage, and check conditions of the work equipment
and hydraulic system. In addition, check whether the wires near the high temperature area are
loose, and there are clearance and dust accumulation.

CAUTION
• Remove the combustible materials around the battery, engine, muffler, turbocharger or other
high temperature parts, otherwise, it may cause fire.
• The leakage of fuel or oil will cause the machine burning.
The following inspection and cleaning shall be performed before starting the engine every day:
1. Check whether the work equipment, cylinder, hose, etc. have cracks and excessive wear or
looseness, and check whether the bucket and arm connections are damaged. If any problem is
discovered, it shall be repaired or replaced.
2. Remove the dirt and debris around the engine, battery and radiator. Check whether there are
dirts around the engine and radiator. In addition, check whether there are combustible materials
(dry leaves, twigs, etc.) around the battery, engine muffler, turbocharger, or other high temperature
parts. If dirts or combustibles are discovered, remove them.
For a method to remove dirt from the radiator, see the “Cleaning and Inspection of the Radiator
and Cooler Fins” on page 5-51.
3. Check for leakage of coolant and oil around the engine.

Check whether the engine has oil leakage and the cooling system has coolant leakage. If any
problem is discovered, repair it.
4. Check whether the hydraulic device, hydraulic tank, hose and adapter have oil leakage.
Check for oil leakage. If any problem is discovered, repair the leaky oil part.
5. Check whether the lower body (track, sprocket, guide wheel, guard board) is damaged and
worn, and whether bolts are loose or roller has oil leakage.
If any problem is discovered, repair it.
6. Check whether the handrail and step are defective, and whether bolts are loose.
If any problem is discovered, repair it. Tighten loose bolts.
7. Check whether the instrument and monitor are defective. Check whether the instrument and
monitor inside the cab are defective.
If any problem is discovered, replace the parts. Remove dirts from the surface.
8. Clean and check the rearview mirror.

Check whether the rearview mirror is damaged. If damaged, repair it. Clean the surface of the mir-
ror and adjust the angle, so as to ensure that the rear area can be seen while sitting on the driver’s
seat.
9. Check seat belt and fixing clamp.

Check whether the seat belt and fixing clamp are damaged or worn. If damaged, replace the part
with a new one.

10.Check whether the bucket with hook (if equipped) is damaged.

Check whether the hook, guide plate, and hook seat are damaged. If any fault is discovered,
please contact the authorized agent of SANY Heavy Machinery for repair.
4.3.1.2 Inspection before start
Always check the items in this section before

starting the engine every day.
Drain water and sediment from the fuel

tank.
1. Open the access door on the right side of

the machine.
2. Place a container at the outlet of the drain

hose [1] to hold discharged fuel.
1
2
3. Open the drain valve [2] to make all sedi-
15041523
ments and water accumulated at the bottom
Fig.4-118
flow out with the fuel.
4. Close the drain valve [2] when there is a

clean fuel flow.
5. Close the access door.
Check and drain out water and sediment in

water separator

the machine. 1
2. Observe it through the transparent shell [1]

to judge the water level and the amount of
2
sediment. If there is water or sediment accu-
3
mulation at the bottom, place a container
CC13040701
under the drain hose [3] to hold discharged
Fig.4-119
water.
3. Release the drain valve [2] for drainage.

4. Tighten the drain valve [2] immediately

when the fuel begins to flow from the drain
hose [3].
NOTE：
• If transparent shell [2] is too dirty or when it is
difficult to see inside, clean the transparent
shell during replacement of the filter
element.
• If drain valve [3] is removed during cleaning,
apply grease to the O-ring [4] and tighten it
until it contacts the bottom. 4
CC13040702
Fig.4-120
Check oil level of the hydraulic tank
WARNING
• When the engine is stopped, the parts and
oil are still very hot, which may cause
scalding. Start operation after they are
cooled down.
• When the filler cap is removed, slowly ro-
tate it to release the internal pressure and
then remove it. CZ335-1103207
Fig.4-121
1. Adjust the work equipment to the position
as shown in the right Figure, and then stop
the engine.
F
2. Move the work equipment travel lever and
travel lever in all directions during the whole
G
trip within 15 s after the engine is stopped to
release the internal pressure.
P

the machine to check the oil lever gauge [G].
CZ335-1103126
Before operation, it is located between H and
L Fig.4-122
(Oil temperature: 10 ~ 30°C (50 ~ 86°F))
Normal operation: It is near H

(Oil temperature: 50 ~ 80°C (122 ~ 176°F))
4. If the oil level is lower than the L line, fill oil

through the filler [F] on the top of the tank.
NOTE：
Stop oil filling when it reaches the H line. This
will damage the hydraulic device and cause
oil spraying. If oil level is higher than the H H
line, stop the engine. After oil is cooled down,
place an oil container below the drain plug [P]
at the bottom of the hydraulic tank, and then
drain the excessive oil from the drain plug.
L
CC13052101
Fig.4-123
Check the coolant level
WARNING
• After the engine is stopped, the coolant will
be very hot and the radiator will have a
high pressure status. If the radiator cap [1]
is removed and the coolant level is
checked at this time, there will be a scald-
ing hazard. Therefore, remove the cap [1]
after it is cooled down. After that, slowly ro-
tate the cap to release the internal
pressure. Fig.4-124
1. When the engine is cold, the coolant level

must be above the internal partition of the ex-
pansion tank. If the coolant level is lower than
the internal partition of the expansion tank,
add coolant to the tank.
2. Tighten the pressure cap after adding the

coolant.
3. If the expansion tank is empty, coolant leak-

age may occur. After inspection, repair it im-
mediately. If there is no fault, add the

antifreeze until the level is above the internal

partition of the expansion tank.
Check oil level of engine oil pan
WARNING
• When the engine is stopped, the parts and
oil are still very hot, which may cause
scalding. Relevant operation can be car-
ried out after they are cooled down.
1. Open the engine hood.

F G
2. Remove the oil dipstick [G] and wipe off oil
on it with a piece of cloth.
3. Insert the oil dipstick [G] completely and

then remove it.
14111904
Fig.4-125
4. The oil level shall be located between the H

and L marks on the oil dipstick [G]. If the oil
level is lower than the L mark, fill oil through
the filler [F].
L H
CZ335-1103131
Fig.4-126

5. If the oil level is above the H mark, drive the

screw end of drain valve adapter in the acces-
sories box into the drain cock P at the bottom
of the oil pan (the more the screw end is driv-
en, the larger the opening is), drain the exces-
sive oil, and then check the oil level.
6. If the oil level is proper, tighten the filler cap

firmly and close the engine hood.
P
15041524
NOTE：
• Before checking oil level after engine opera- Fig.4-127
tion, wait at least 15 minutes after the engine
stop.
• Keep the machine level before the
inspection.
Check wires
CAUTION
• If the fuse has been burnt frequently or if
there is a short circuit in the wire, please
contact the authorized agent of SANY
Heavy Machinery to find the cause and re-
pair it.
• Keep the upper surface of the battery
clean, and check the air vent on the battery
cap. If the battery cap is blocked by dirt or
dust, flush it to clean the air vent.
Check whether the fuse is damaged, whether

the specified capacity fuse is used, whether
the wire has trace of open circuit or short cir-
cuit, or whether the cable cladding is
damaged.
Check whether the terminal is loose. If loose,

tighten them.
In addition, pay special attention to wires

when checking batteries, motors, starting mo-
tors and alternators. Be sure to check whether
there is a flammable accumulation around the

battery. If flammable material is discovered,

remove it immediately.
Check the fuel level
WARNING
• When filling fuel, do not spill or overflow
the fuel. This will cause a fire.
• Fuel is flammable. Do not make open fire
close to fuel. E F
• If the fuel is spilled, clean it thoroughly. If
the fuel flows to the ground or sand, re-
CZ215-1303002
move it.
Fig.4-128
1. Turn the ignition switch to the [ON] position,
and check the fuel level indicated on the dis-
play. After inspection, turn the switch back to
[OFF] position.
2. If the fuel level is low, release the filler cap

[F] on the fuel tank.
F
• Add the fuel until the fuel level is about
50mm from the top of the fuel tank, and
then tighten the filler cap [F].
• When the fuel amount is less than 10%, the
display will send an alarm.
CZ335-1103134
Fig.4-129
CZ335-1103136
Fig.4-130

NOTE：
• If the air vent on the cap is blocked, the pres-
sure in the tank will drop and the fuel will not
flow. Clean the air vent frequently.
• When the lock cap is tightened, the stroke is
larger. Ensure that the lock cap is rotated
properly, and then turn the key to lock the
lock cap. If the key is removed when rotation
is not completed, the latch bolt will touch on
the inner wall of the filler to damage the lock
cylinder.
• It is necessary to ensure the cleanness of
the sealing ring in the lock cap. If the sealing
ring is stained with impurities including iron
chips and stones, it will be easily damaged
during tightening, causing improper sealing
of the lock cap.
Check the working lamp switch
Check whether the working lamp can be nor-

mally turned on.
Check for dirt or damage.
If the lamp can’t be turned on, the bulb may

be burnt out or broken, please contact the au-
thorized agent of SANY Heavy Machinery for
repair.
CC13040203
1. Turn the ignition switch to the [ON] position.

Fig.4-131
2. Turn on the working lamp switch to check
whether the working lamp is turned on.

Check the horn
2. Check whether the horn makes a sound im-

mediately after the horn switch is pressed on,
and confirm whether the sound is normal. If
the horn doesn’t make a sound or its sound is
abnormal, please contact the authorized
CC13040209
agent of SANY Heavy Machinery for repair.
Fig.4-132
4.3.1.3 Adjustment before operation
Driver’s seat
D
Before starting operation or after changing the
driver, adjust the seat position to ensure that
the driver can operate the travel lever, pedal
and switch freely and easily when sitting in
the seat.
[A] Depth adjustment of seat E
Pull up the pull rod [1] to move the seat to the

required position, and then release it. A
C
Adjustment distance: 200 mm (10 mm per
grade)
[B] Overall dept adjustment of seat
Pull up the pull rod [2] to adjust it to the re-

1
quired position, and then release it. In this
case, the driver’s seat, left and right armrest
3 2 4
boxes and the pilot lock rod will slide together.
B CZ335-1103139
[C] Adjustment of suspension (if equipped)
Fig.4-133
Turn the shifter lever [3] to the left, and the
suspension will become harder to suit the
heavier driver. Turn the shifter lever [3] to the
right, and the suspension will become softer
to suit the lighter driver.

NOTE：
In order to achieve the best adjustment, adjust
the reading (kg) of dial [4] to the position cor-
responding to the driver’s weight.
[D] Adjustment of rear seatback
Pull up the handle [5], place the seatback

back to the best position for easy operation,
and then release the handle.
NOTE：
When adjusting the inclination of the seat-
5
back, be careful not to interfere with the rear
HVAC panel, and be careful not to make the
handrail contact with the operation lever.
CZ335-1103140
Fig.4-134
[E] Adjustment of handrail angle
Rotate the adjustment dial [7] at the bottom of

6
the armrest [6] to adjust the angle of the arm-
rest to the required position.
Lift the armrest to the vertical position to en-

sure that the driver can leave the seat. 7
Armrest adjustment angle range: 40°
CC13031516
Fig.4-135

Rearview mirror
WARNING B A
• Be sure to adjust the rearview mirror be-
fore start. If no correct adjustment is made,
the sight line can’t be guaranteed, and per-
sonal injury may be caused.
The installation position of the rearview mirror

is as shown in the Figure.
CZ335-1103142
Fig.4-136
Rearview mirror [A]
Adjust installation of the rearview mirror [A] to

ensure the personnel at the left rear side of
the machine can be seen. 2
• Install the rearview mirror [A] in the position 1
as shown in the right Figure.

• Rotate the fixing rod [1] around the lever [4]
3
to a proper position, and fix the fixing rod
[1].
4
• If the mirror can’t move smoothly when ad- CZ335-1103143
justing the angle, release the fixing bolt [2]

Fig.4-137
and the fastening lever bolt [3] of mirror.
Tightening torque of bolt [2] x: 4.0~5.4N·m
（0.41~0.55kgf·m）
• When adjusting the angle of the rearview

mirror, the sight line entering the mirror on
the side of the machine shall prevail, as
shown in the right Figure.
CZ335-1103144
Fig.4-138

Rearview mirror [B]
Adjust installation of the rearview mirror [B] to

ensure the personnel at the right rear side of
the machine can be seen. 5
• Install the rearview mirror [B] in the position
as shown in the right Figure. 6
M
M：120mm
• If the mirror can’t move smoothly when ad-
justing the angle, release the fixing bolt [5]
and the fastening lever bolt [6] of mirror. CZ335-1103145
Tightening torque of bolt [5] x: 4.0~5.4N·m

Fig.4-139
（0.41~0.55kgf·m）
• When adjusting the angle of the rearview

mirror, the sight line entering the mirror on
the side of the machine shall prevail, as
Seat belt
WARNING
• Before using the seat belt, check whether
the seat belt and its mounting seat are de-
fective, and replace them if worn or CZ335-1103146
damaged.
Fig.4-140
• Even if the seat belt looks normal, it shall
be replaced every 3 years. The production
date of the seat belt is marked on its back.
• Wear seat belt during operation.
• The seat belt can’t be twisted when it is
fastened.
NOTE：
The seat belt is supplied with a winding de-
vice, so it is unnecessary to adjust the length.

1. Fasten the seat belt.
Hold the seat belt clamp [2] and pull the seat
belt out from the winding device [1]. Ensure
4 3 2 1
that the seat belt is not twisted, and then insert
the latch bolt [3] into the latch [4].
SS
Pull the seat belt gently to ensure that it is
PRE
fastened.
2. Release the seat belt CZ335-1103147
Press down the red part on the latch [4], and Fig.4-141
the latch bolt [3] will automatically pop up from
the lock [4].
The seat belt will be automatically involved in

the winding device [1]. Hold the seat belt
clamp [2] to slowly wind the seat belt into the
winding device [1].
4.3.1.4 Operation before engine start
WARNING
• Before engine start, check whether the
safety lock control lever is firmly located at
the locking position.
• If the safety lock control lever is not firmly
locked and it knocks with the travel lever or
pedal during engine start, the machine will
move accidentally and cause serious
accidents.
• When standing from the driver’s seat, be
sure to set the safety lock control lever to
the locking position regardless of whether
the engine is running.

1. Check whether the safety lock control lever Fig.4-142

is located at the “LOCK” position.
2. Check whether the travel lever and pedal

are in the “Neutral” position. If there is no con-
tact with the travel lever or pedal, they shall
be located in the “Neutral” position.
3. Turn the key to the [ON] position.
CC13031403
4. Monitor the status of the machine through

the main page of the display. For details of the
display, see the “Display Screen” section.
• ON
If there is any fault, the alarm lamp will be OFF
STA
T
on.
HEA
RT
• In this case, if the fault code is displayed,
the corresponding item of the fault code
shall be checked immediately.
• If there is no fault code, the fault cause may
CC13031804
be: too high engine coolant temperature;
too high or low engine oil pressure. Fig.4-143

4.3.2 Engine start
WARNING
• Start the engine only when sitting in the
driver’ s seat.
• Do not start the engine by short circuiting
the engine. This can cause serious person-
al injury or fire.
• Ensure that there are no personnel or ob-
stacles in the surrounding area, and then
make the horn sound and start the engine.
• Do not use start-assisted liquid, because it
will cause explosions.
• The exhaust gas is poisonous. When start-
ing the engine in enclosed space, special
attention shall be paid to ensure good
ventilation.
• Before starting the engine, check whether

the fuel control knob is located at a low idle
speed [MIN] position. If the fuel control knob
START X
is located at the full speed [MAX] position, MA
ON
the engine start will suddenly accelerate
OFF
and damage the engine parts.

AT
HE
NIM
• The ignition switch key can’t be kept at the
[START] position for more than 10 s
consecutively.
CC13031502
• If the engine is not started, wait for at least
1 minute before restart. Fig.4-144
• After the engine is started, it can be oper-
ated after the engine oil pressure value is
within the normal range. When the engine
oil pressure is abnormal, do not operate the
travel lever or pedal, and stop the machine
immediately for inspection.

1. Check whether the safety lock control lever

is located at the “LOCK” position. If the safety
lock control lever is in the “Unlocking” posi-
tion, the engine can’t be started.
CC13031403
Fig.4-145
2. Set the fuel control knob to a low idle speed

[MIN] position.
MA
X
MIN
CC13031401
Fig.4-146
3. Turn the ignition switch key to the [ON]

position.
NOTE： ON
OFF
When the ambient temperature is lower than
STA
T
HEA
10℃ or when required, the engine shall be

RT
preheated before start.
CC13031804
Fig.4-147

4. Turn the ignition switch to the [START] posi-

tion to start the engine.
ON
OFF
STA
T
HEA
RT
CC13031801
Fig.4-148
5. After the engine starts, release the ignition

switch key, and the key will automatically re-
turn to the [ON] position.
ON
OFF
NOTE：
STA
T
HEA
If the ambient temperature is low, the engine
RT
can’t be started after the ignition switch key
remains in the [ON] position for 10 s. If this
condition occurs, wait for at least 1 minute be-
fore restart.
CC13031802
Fig.4-149
6. Even the engine is started, wait for the en-

gine oil pressure alarm release. When the en-
gine oil pressure is abnormal, do not touch
the travel lever or pedal.
NOTE：
If the engine oil pressure is still abnormal after
4~5 s, the engine shall be stopped immedi-
ately to check the oil level and oil leakage,
and take necessary measures.
4.3.3 Engine preheating
• Turn the accelerator rotary switch to [MIN]

position, and turn the ignition switch to [ON]
position. At this time, the engine will be
warmed up automatically. After warm-up,
the engine can be started.

• After warm-up, turn the ignition switch to

[START] position to start the engine.
• If the engine is not started, wait for at least
1 minute before next warm-up and start
attempt.
4.3.4 Warm-up operation
WARNING
• Turn the ignition switch to the OFF position to stop the engine when there is an emergency or
the engine works abnormally or it has other faults.
• When the hydraulic oil temperature is low, do not operate the travel lever or pedal suddenly. Be
sure to carry out warm-up operation until the hydraulic oil temperature reaches the proper
temperature.
• If no complete warm-up operation is carried out, the machine will have no reaction or sudden
and quick action during operation, resulting in serious accidents. The complete warm-up shall
be carried out especially in the cold region.
• Before warm-up operation is completed, do not make the engine suddenly accelerate. Do not
run the engine at low speed or high speed for more than 20 minutes. This will cause oil leakage
of oil supply pipe of the turbocharger, which may lead to a fire hazard. If the engine shall be op-
erated at idle speed, the load shall be always applied to run the engine at medium speed.
After starting the engine, do not start the operation immediately, first carry out the following opera-
tions and inspection:
1. Adjust the accelerator rotary switch to run the engine at a low idle speed (about 850 rpm) for
about 5 minutes.
2. Adjust the throttle knob to make the engine run at medium speed (about 1100 rpm), and then
slowly operate the bucket back and forth for 5 minutes.
3. Adjust the throttle knob to make the engine run at high speed, and then operate the boom, arm
and bucket for 5~10 minutes.
4. Complete the operation of the actions of the excavator for several times, and its warm-up will be
completed.
5. Check whether displays of the instrument are normal after the warm-up operation. If coolant
temperature (see the display) and hydraulic oil temperature (50~80℃) fail to reach the normal val-
ue, continue to carryout warm-up operation.
6. Check whether the color, noise, or vibration of the exhaust is abnormal. If abnormal, repair it.

4.3.5 Stop the engine
CAUTION
• If the engine is not stopped under the idle
status, its service life will be shortened. In
case of emergency, do not emergently stop
the engine at high speed. Otherwise, the
cylinder head will have fatigue crack and
the supercharger bearing will be burnt.
1. Operate the engine at a low idle speed for

about 5 minutes to gradually cool it down.
ON
2. Turn the ignition switch to the [OFF] posi- OFF
STA
T
HEA
tion, stop the engine, and remove the key
RT
from the ignition switch.
NOTE：
If the engine is too hot, do not suddenly stop
CC13031803
it, but run it at low idle speed to cool it down
and then stop it. Fig.4-150
4.3.6 Machine operation
4.3.6.1 General
WARNING
• Before moving the machine, check
whether the area around the machine is
safety and sound the horn.
C
• No one is allowed to enter the area around
the machine.
• Remove any obstacles on the traveling
path.
• There is a blind spot at the back of the ma- A B
chine, so pay special attention to it during CC13031518
reverse traveling.
Fig.4-151
Before operating the travel lever or traveling
pedal, it is necessary to confirm that the guide
wheel [A] is in front of the machine and the

sprocket [B] is at the end of the machine [C]. If

the sprocket is located in front of the machine,
the driving direction of the machine will be op-
posite to the operation direction of the travel
lever or the traveling pedal. (The front and
rear traveling directions are opposite, and the
left and right steering directions are also
opposite)
4.3.6.2 Preparation of moving machine
1. Turn the fuel control knob to the MAX posi-

tion to the required throttle position to in-
crease the engine speed. MA
X
MIN
CC13031507
Fig.4-152

2. Turn the safety lock control lever to the “Un-

locking” position, and retract the work equip-
ment and lift it up to 40~50cm from the
ground. As shown on the right Figure.
NOTE：
If the sight line on the right side is poor, lift the
boom to ensure a better sight line.
CC13031404
Fig.4-153
40~50cm
CC13050601
Fig.4-154
4.3.6.3 Move machine
Forward
• Push the left and right travel levers forwards
or step down the front part of the left and
right pedals at the same time to move the
machine forwards.
CC13031508
Fig.4-155

Reverse
• Pull the left and right travel levers back-
wards or step down the rear part of the left
and right pedals at the same time to move
the machine backwards.
CC13031509
Fig.4-156
NOTE：
• If the sprocket is located in front of the ma-
chine, when operating the travel lever or the
pedal, the driving direction of the machine
will be opposite to the operation direction of
the travel lever or the traveling pedal.
• Operate the travel pedal or pedal in the same
direction and in the same range to ensure
that the machine runs in a straight line.
• If the traveling speed of the machine is ab-
normal at low temperature, carry out com-
plete warm-up operation. In addition, if the
undercarriage traveling body is blocked by
mud and the traveling speed of the machine
is abnormal, remove the dirt.
4.3.6.4 Stop machine
CAUTION
• Avoid stopping the machine suddenly.
• When stopping the machine, reserve
enough space to leave the machine.

Release the left and right travel levers or ped-

als at the same time to stop the machine.
N
The travel lever or pedal will automatically re-
turn to the neutral [N] position after release.
N
CZ335-1103169
Fig.4-157
4.3.7 Machine steering
4.3.7.1 General
Check the sprocket position before operating

the travel lever or traveling pedal. If the
sprocket is located in front part, the operation
direction of the travel lever or pedal will be op-
posite to the movement direction of the
machine.
Try to avoid sudden change of direction. In

particular, stop the machine before steering in
case of reverse rotation (in-situ steering).
4.3.7.2 Turn the machine when it stops
Left turn
Push the right travel lever forwards, and the

right track will travel forwards, and the ma-
chine will turn to left;
CC13031510
Fig.4-158

Pull the left travel lever backwards, and the

left track will travel backwards, and the ma-
chine will turn to left.
CC13031511
Fig.4-159
Right turn
Push the left travel lever forwards, and the left

track will travel forwards, and the machine will
turn to right;
CC13031512
Fig.4-160
Pull the right travel lever backwards, and the

right track will travel backwards, and the ma-
chine will turn to right.
CC13031513
Fig.4-161

4.3.7.3 In-situ steering
In-situ left turn

• Push the right travel lever forwards, and pull
back the left travel lever.
CC13031514
Fig.4-162
In-situ right turn

• Push the left travel lever forwards, and pull
back the right travel lever.
CC13031515
Fig.4-163
4.3.8 Control and operation of work equipment
CAUTION
• When the engine speed has been reduced
by the automatic idle speed function, if the
travel lever is operated, the engine speed
will suddenly rise, therefore, the travel lev-
er shall be operated carefully.
The control and operation of the work equip-

ment will be completed through travel levers
of the left and right work equipment.

When the travel lever is released, it will return

to the neutral position, and the work equip-
ment will also remain in that position.
• Arm control
Operate the travel lever of the left work equip-

ment forwards or backwards to control action
of the arm.
CZ335-1103175
Fig.4-164
• Slewing control
Move the left joystick leftwards or rightwards

to control swing of the superstructure.
CZ335-1103176
Fig.4-165
• Boom control
Move the right joystick forwards or backwards

to control action of the boom.
CZ335-1103177
Fig.4-166

• Bucket control
Move the right joystick leftwards or rightwards

to control action of the bucket.
When the work equipment travel lever returns

back to the neutral position, even the fuel con-
trol knob is set to the full speed position within
5 s after the operation stops, the automatic
idle speed mechanism will act and reduce the
CZ335-1103178
engine speed to idle speed.
Fig.4-167
NOTE：
The control oil circuit of the machine is
equipped with an accumulator. If the starting
switch key is turned to the [ON] position and
the safety lock control lever is turned to the
“Unlocking” position within 15 s after engine
stop, even though the engine is stopped, the
travel lever can be operated to lower down
the work equipment to the ground.
This step can also be used to release the re-
sidual pressure in oil circuit of the hydraulic
cylinder or to remove boom after the machine
loaded onto the trailer.
4.3.9 Prohibited operation
CAUTION
• When the machine is traveling, if it is nec-
essary to operate travel lever of the work
equipment, stop the machine and then op-
erate the travel lever.
• If any travel lever shall be operated at the
automatic idle speed, the engine speed will
suddenly rise.

The operation with slewing force is

prohibited
Do not compress the ground or break objects

with slewing force. This will be dangerous,
and will dramatically shorten the service life of
the machine.
CZ335-1103181
Fig.4-168
The operation with traveling force is

prohibited
Do not insert the bucket into the ground and

use the traveling force for digging. This will
damage the machine or the work equipment.
CZ335-1103182
Fig.4-169

The operation when the hydraulic cylinder

reaches the end of the stroke is prohibited
If the cylinder piston rod is operated to the

end of its stroke, the use of the work equip-
ment and the impact of some external force
will damage the hydraulic cylinder and cause
personal injury. Avoid operation when the hy-
draulic cylinder is fully retracted or fully
extended.
CZ335-1103183
Fig.4-170
The operation with the bucket drop force

is prohibited
1. Do not use the drop force of the bucket for

digging, crushing or piling. This will dramati-
cally shorten the service life of the machine.
2. To avoid damage to the hydraulic cylinder,

do not hit the ground with a bucket or tamp it
with a shovel when the bucket oil cylinder is
fully extended (the bucket is fully retracted).
CZ335-1103184
Fig.4-171
It is forbidden to dig hard rock ground
Do not try to dig the hard rock ground directly,

and it is recommended to break it in other
ways before digging. This will not only reduce
the damage to the machine, but also be
economical.

The operation with the deadweight of the

machine is prohibited
Do not dig with the force arising from dead-

weight of the machine.
CZ335-1103185
Fig.4-172
It is not allowed to suddenly switch the

travel lever or pedal during traveling at
high speed
A 3
1. Do not operate the travel lever or pedal sud-
2
denly to make the machine move quickly. 1
B
2. Do not suddenly switch the travel lever or
pedal to the reverse [B] from forward [A] (or
from reverse [B] to forward [A]).
CZ335-1103186
3. Do not to suddenly release the travel lever
Fig.4-173
or pedal during traveling at high speed to stop
the machine.

4.3.10 Allowed water depth
When the machine is driven out from the

water, if the slope angle is larger than 15°, the
rear part of the upper slewing platform will fall
into the water, the engine fan will touch the
water, and the fan will be damaged.
Be careful when driving the machine out from

the water.
CZ335-1103189
Fig.4-174
• Do not drive the machine into the water

deeper than the center of the sprocket [1].
• Apply lubricating grease to the parts that
have been immersed in water for a long
time until the old lubricating grease is com-
pletely extruded from the bearing (espe-
cially around the bucket pin).
• The machine can be operated in water only
when the work foundation of the machine 1
CZ335-1103190
has sufficient strength to avoid water depth
higher than center of the sprocket in case of Fig.4-175
sinking of the machine.
• If the slewing support, the slewing gear and
the center swivel joint are immersed in
water, remove the drain plug to remove the
muddy water, sweep the slewing area and
install the plug. Lubricate the internal slew-
ing mesh gear and slewing bearing.
4.3.11 Operation on the slope
4.3.11.1 General
Be sure to operate or drive the machine in the

following correct ways, the machine can be
stopped safely even when the machine is slip-
ping or becoming unstable.

WARNING
• When working on a slope, turning or opera-
tion of the work equipment will make the
machine unbalanced and tilting, so this op-
eration shall be avoided.
• It is very dangerous to slew the loaded
bucket downhill. If this operation is re-
quired, a platform shall be built on the
CZ335-1102046
slope with soil to make the machine remain
horizontal during operation. Fig.4-176
• Do not drive the machine on a steep slope
or downhill, it may turn over.
• Do not turn the machine on a slope or drive
it across a slope. Be sure to carry out these
operations on a flat ground. It may be a lit-
tle bit further, but it will be safe.
• When driving the machine uphill, if the
track shoe slips or only the force of the
track is available, the machine can't be
CZ335-1103192
driven uphill. Do not use the pull of the arm
to help drive the machine uphill. Fig.4-177
• When the slope angle is larger than 30°,
the engine lubrication will be insufficient.
1. When driving down the steep slope, use the

travel lever and fuel control knob to keep the
low traveling speed. When driving down the
steep slope with an angle larger than 15°, ad-
just the work equipment to the position as
shown in the right Figure and reduce the en-
gine speed.
CZ335-1102039
Fig.4-178

2. When driving up the steep slope, extend

the work equipment to the front part to ensure
balance. Keep the work equipment about
20~30 cm higher than the ground and ensure
traveling at low speed.
CZ335-1102040
Fig.4-179
4.3.11.2 Downhill traveling
• Turn the travel lever to the neutral position

to ensure that the brake can work
automatically.
4.3.11.3 Engine flameout on the slope
• If the engine flames out during the uphill

travel, turn the travel lever to the neutral po-
sition, lower the bucket to the ground, stop
the machine, and then restart the engine.
4.3.11.4 Cab door on the slope
• If the engine is stopped when the machine

is on the slope, do not use travel lever of
the left work equipment for slewing. The
upper slewing platform will be rotated under
its own deadweight.
• When the machine is on the slope, do not
open or close the cab door, which will
change the machine stress suddenly. Be
sure to keep the cab door open or closed.

4.3.12 Drive the machine out of the mud
4.3.12.1 General
Be careful to avoid getting stuck in the mud. If

the machine is stuck in the mud, drive the ma-
chine out with the following methods.
4.3.12.2 Track on one side gets stuck in the mud
Ensure that the bottom of the bucket is in con-

tact with the ground when the machine is
jacked up with the boom or the arm. The angle
between the boom and arm shall be 90°
~110°.
It also applies when using reverse mounted

bucket.
When only track on one side gets stuck in the

mud, jack up the track with a bucket, and then
pave a board or log on it and drive out the CZ335-1103195
machine.
Fig.4-180
4.3.12.3 Tracks on both sides get stuck in the mud
When tracks on both sides get stuck in the

mud and slip and the machine can't move,
pave the board with the above method, and
dig the bucket into the ground ahead. After
that, retract the arm and turn the travel lever
to the “Forward” position with the normal dig-
ging operation methods, and drive out the
machine.
CZ335-1103196
Fig.4-181

4.3.13 Recommended purpose
4.3.13.1 General
In addition to the following purposes, the oper-

ation range can be increased with the
accessories.
4.3.13.2 Backhoe operation
The backhoe is suitable for digging of area be-

low the machine.
When the machine is in the status shown in

the right figure (namely, both the angle be- 90°
tween the bucket cylinder and link and the an-
90°
gle between the arm cylinder and arm are
90°), the maximum digging strength can be
obtained from the cylinder thrust.
When effectively using this angle during dig- CZ335-1103197

ging, the work efficiency can be fully played.
Fig.4-182
The arm digging range includes the area be-

tween 45° away from the machine and 30° 45° 30°
close to the machine.
Depending on the digging depth, the above

range may be slightly different, but it shall be
kept in the above range as much as possible,
and do not operate the cylinder to the end of
its stroke.
CZ335-1103198
Fig.4-183

4.3.13.3 Ditching work
• The ditching operation can be carried out

effectively by installing a bucket that
matches with the digging operation and ad-
justing the track to be parallel with the line
of the trench to be dug.
• When digging a wide trench, both sides
shall be dug, and then the central part shall
be cleared.
• When digging in the longitudinal direction,
CZ335-1103199
the travel motor shall be placed in the rear
part to ensure that the stability and lifting Fig.4-184
capacity of the machine is the maximum.
• During digging operation, adjust the track to

be vertical to the shoulder or cliff and locate
the sprocket at the back of the cab, so as to
ensure that the machine can be easily
evacuated when abnormality occurs
CZ335-1102049
Fig.4-185
4.3.13.4 Loading operation
When the slewing angle is smaller, park the

dump truck in a place visible to the driver to
improve work efficiency.
It is more convenient to start loading from the

rear part of the dump truck than from the side,
and the loading capacity is higher.
CZ335-1103200
Fig.4-186

4.3.14 Parking
WARNING
• If accidentally touching the travel lever, the
machine will suddenly move, which may
cause serious accidents.
• Before leaving the cab, be sure to turn the
safety lock control lever to the “LOCK”
position.
When parking the machine, choose a flat, sol-

id ground and avoid dangerous places. If the
machine shall be parked on the slope, place a
cushion block under the track shoe (as shown
in the Figure). The bucket can be inserted into
120°
the ground as an auxiliary safety measure.
CZ335-1102055
Fig.4-187
1. Turn the left and right travel levers to the

neutral [N] position to stop the machine.
CZ335-1103169
Fig.4-188

2. Turn the fuel control knob to a low idle

speed [MIN] position to reduce the engine
speed. MA
X
MIN
CC13031401
Fig.4-189
3. Lower down the bucket horizontally until its

bottom reaches the ground.
CZ335-1103207
Fig.4-190

CC13031403
Fig.4-191

5. Check the engine coolant temperature (as

shown in the Figure) and the engine oil pres-
sure through the display.
• If the coolant thermometer is in the red
range, cool down the coolant until the nee-
dle reaches the yellow range, and then stop
the engine. C H
• If the alarm prompt is displayed on the dis-
play and abnormal engine oil pressure is
CC13050802-1
determined, stop the engine immediately.
Fig.4-192
6. Stop the engine.
4.3.15 Machine inspection after daily work
1. Check the machine and the work equip-

ment, outside and lower body for leakage of
oil or coolant. If any problem is discovered, re-
pair it.
2. Fill up the fuel tank.
3. Check whether there are paper or other im-

purities in the engine room. Remove paper or
other impurities to avoid fire hazard.
4. Remove dirt from the lower body.
5. If the ambient temperature is lower than

-35℃, be sure to drain coolant in the radiator
and engine (the freezing point of antifreeze
used for SANY Heavy Machinery is -35℃).

4.3.16 Locking
Be sure to lock the following positions
1. Cab door
Close windows properly
3
2. Fuel tank filler

4
3. Engine hood 5
7
4. Tool box cover 1
5. Left door of the machine CZ335-1103208
6. Right door of the machine Fig.4-193
7. HVAC “Fresh Air” inlet
NOTE：
Lock and unlock these positions with the igni-
2
tion switch key.
6
CZ335-1103209
Fig.4-194
4.3.17 Operation in cold season
4.3.17.1 Description of operation in cold weather
The engine will not be able to start and the coolant may be frozen in a low temperature environ-
ment, so it shall be operated according to the following content.
Fuel and lubricating oil
All the parts shall be applied with low viscosity fuel and lubricating oil.
For details of viscosity provisions, see the “Recommended Fuel, Coolant and Lubricating Oil” on
page 5-9.

Coolant of cooling system
WARNING
• The antifreeze is poisonous. Be careful not to get it on your eyes or skin. If your eyes or skin
are stained with it, rinse with plenty of water and see the doctor immediately.
• When changing coolant or treating coolant containing antifreeze drained during radiator repair,
please contact the dealers authorized by Sany Heavy Machinery Co., Ltd. or professional com-
pany for treatment. Do not drain the antifreeze into the sewer or spill it on the ground because it
is toxic.
• The antifreeze is flammable. Do not get close to open fire. Do not smoke when dealing with
antifreeze.
NOTE：
Please use genuine SANY TEEC-L35 antifreeze as coolant. In principle, we do not recommend
using any coolant other than the genuine full-effect antifreeze of Sany Heavy Machinery Co., Ltd.
For details on the mixing ratio of the antifreeze during coolant change, see the “Coolant of Cooling
System” on page 5-6.
Battery
When the ambient temperature drops, the battery capacity will also be reduced. Keep the battery
capacity as close to 100% as possible. Do not keep the battery at a low temperature for a long time
to avoid difficult start of the machine.
Because the battery capacity will drop at low temperature, it is necessary to cover the battery, or
remove it from the machine, store it in a warmer site, and then reinstall the battery when using the
machine.
4.3.17.2 After daily work
In order to prevent movement failure of the

machine on the next day due to frozen mud
and water on the lower body, the following
precautions shall be observed:
• Remove all mud and water from the body.
In particular, the hydraulic cylinder piston
rod shall be cleaned to prevent mud, dirt or
water on the piston rod from entering the
seal and damaging it.
• The machine shall parked on a hard, dry
ground. If possible, park the machine on the
board and prevent the track from freezing

on the ground to ensure that the machine

can be moved on the next day.
• Turn on the drain valve to drain water accu-
mulated in the fuel system to prevent
freezing.
• Fill up the fuel tank. This can minimize
moisture condensation in the tank when the
temperature drops.
• After operation in the water or in the mud,
remove the water on the lower body accord-
ing to the following instructions to extend
the service life of the lower body.
1. When the engine runs at idle speed, rotate

the upper structure by 90° to locate the work
equipment in the side of the track.
2. As shown in the Figure, lift the machine and

lift the track slightly off the ground and idly run
the track. Repeat this operation on both left
and right tracks.
WARNING CZ335-1103210
• It is dangerous when the track is running Fig.4-195

idly, and the personnel shall keep a certain
distance from the track.
4.3.17.3 After the cold season
When the seasons change and it becomes

warmer, operate according to the following
content:
• Replace fuel and lubricant with specified
viscosity oil.
For details, see the “Recommended Fuel,
Coolant and Lubricating Oil” on page 5-9.

4.3.18 Long-term storage
4.3.18.1 Before storage
When the machine is stored (for more than 1

month), it shall be changed to the position as
shown in the right Figure to protect the cylin-
der piston rod and prevent it from rusting.
When the machine is stored for a long time

(for more than 1 month), operate according to
the following content:
• Clean and flush all the parts, and then store
the machine indoors. If the machine has to
be stored outdoors, choose a flat ground
CZ335-1103211
and cover the machine with canvas.
• Fill up the fuel tank to prevent moisture Fig.4-196
accumulation.
• Before storage, lubricate and replace oil.
• Apply lubricating grease to the exposed part
of the piston rod of the hydraulic cylinder.
• Turn the negative breaker to OFF. Discon-
nect the negative terminal of the battery
and cover it, or remove the battery from the
machine and store it separately.
• For machines equipped with accessories,
the accessory control pedal shall be turned
to a locking position.
• To prevent rust, fill the coolant recom-
mended by SANY Heavy Machinery.
4.3.18.2 During storage
WARNING
• When the machine is indoors and it needs
to anti-rust operation, open doors and win-
dows to improve ventilation and prevent
gas poisoning.
• During storage, the machine shall be oper-

ated once a month and shall be driven in a
short distance, and the parts shall be

coated with a new oil film. In addition, the

battery shall be charged.
• Wipe off all lubricating grease on the piston
rod of the hydraulic cylinder prior to the
work equipment operation.
• If the machine is equipped with HVAC, op-
erate the HVAC for 3-5 minutes every
month to lubricate all parts of the HVAC
compressor. The engine shall be operate at
a low idle speed when the HVAC is oper-
ated. In addition, the refrigerant shall be
checked twice a year.
4.3.18.3 After storage
If the machine is stored for a long time, but it

is not subject to anti-rust operation every
month, please contact the authorized agent of
SANY Heavy Machinery before reuse. When
reusing the machine after long-term storage,
please observe the following content before
use:
• Wipe off lubricating grease of the piston rod
of the hydraulic cylinder.
• Fill all lubricating parts with oil and lubricat-
ing grease.
Fig.4-197
• Turn the negative breaker to ON.
• When the machine is stored for a long time,
the moisture in the air will be mixed with oil.
Check the oil before and after starting the
engine. If there is water in the oil, drain the
water completely and timely.
4.3.18.4 Start the engine after long-term storage
When the engine is started after long-term

storage, it shall be fully warmed up.
For details, see the “Warm-up Operation” on

page 4-76.

4.4 Transportation
4.4.1 General
• When transporting machines, comply with

all relevant laws and regulations, and pay
attention to safety.
4.4.2 Transportation method
• Select a transportation method that

matches the weight and size provided in the
“Technical Specification” section.
• The weight and size provided in the “Tech-
nical Specification” may vary depending on
the type of track shoe, bucket or other
accessories.
• For details of transportation of machines
equipped with the cab protection cover,
please contact the authorized agent of
SANY Heavy Machinery.

4.4.3 Machine loading and unloading machine with trailer
4.4.3.1 General
Be sure to observe the following items of the

access board and trailer platform:
• Use access board with sufficient width,
length, thickness and strength and with a
maximum slope of 15° for loading and
unloading.
• When using the accumulated soil, it is nec-
essary to fully compact the accumulated
soil to prevent the slope from collapsing.
• To prevent the machine from slipping on the CZ335-1103227
access board, clean the track and access
board of the machine before loading and Fig.4-198
unloading.
• If there is water, snow, lubricating grease,
oil or ice on the surface of access board,
the machine may slip.
CZ335-1103228
Fig.4-199

4.4.3.2 Loading
1. It can only be loaded and unloaded on a

solid and flat ground. Keep a safe distance
from the roadside.
2. Apply a brake to the trailer and place a

cushion block [1] under the tyre to prevent the
trailer from moving. 2
• Place the left and right access boards [2] to
make them parallel to each other and equal 1
4
to the left and right spacing of the trailer 3
center [3]. The maximum installation Angle CZ335-1103229

[4] will be 15°. If the access board is bent
Fig.4-200
significantly under the weight of the ma-
chine, place a cushion block under the ac-
cess board to prevent the access board
from bending.
3. Switch the traveling speed to the low speed

status by pressing down the function key of
the display, and disable the automatic idle MA
speed. X
MIN
4. Turn the fuel control knob to the [MIN] posi-

tion, and set the engine speed to low idle
speed.
WARNING
CC13031401
• When driving the machine up or down the
trailer, the automatic idle function shall be Fig.4-201
canceled. If the automatic idle speed func-
tion is enabled, the speed of the engine will
change dramatically.
trailer, the traveling speed shall be kept in
the “Low Speed” mode. Do not switch the
traveling speed randomly.

5. If the machine is equipped with the work

equipment, place the work equipment in the
front part, and drive the machine forwards to
the access board. If there is no work equip-
ment, drive the machine backwards to the ac-
90°-11 0°
cess board.
Support the bucket onto the trailer immedi-

ately after the machine is driven on the access
board.
CZ335-1103231
Especially in case of backward traveling, be
sure to follow the instructions and signals of Fig.4-202
the commander.
WARNING
• Do not adjust direction on the access
board, otherwise, the machine will turn
over.
• Do not operate any control lever other than
the travel lever on the access board.
• If needed, drive the machine to the ground
away from the access board or back to the
CZ335-1103232
trailer before direction adjustment.
Fig.4-203
6. Ensure that the machine is in a straight line

with the access board and the centerline of
the machine corresponds to that of the trailer
before the machine is driven on the access
board.
Slowly drive the machine in the direction of

the access board.
Lower down the work equipment as much as

possible provided no impact is made.

7. Drive the machine slowly forwards until all

the tracks are located on the trailer and firmly
contact with the flat plate.
8. When the machine is passing the rear

wheel of the trailer, the machine will lean for-
ward. Be slow and careful, and do not make
the work equipment touch the trailer body.
9. Slightly lift the bucket, retract the arm and

keep it in the lower part, and then slowly rotate
CZ335-1103233
the upper structure by 180°.
Fig.4-204
10.Fully extend the bucket cylinder and arm
cylinder, and then slowly lower down the
boom.
11.Place a wooden cushion block on one end

of the bucket cylinder to prevent it from touch-
ing the baseplate and damaging the cylinder.
CZ335-1102060
Fig.4-205
4.4.3.3 Secure the machine
• In order to protect the bucket cylinder dur-

ing transportation, place the wood under
the top end of the bucket link to prevent
damage to the bucket cylinder and work
equipment due to direct contact of the buck-
et cylinder with the trailer flatbed and ship
deck.
• Check whether the engine hood latch is
locked. If the engine hood is not locked, it
will be opened during transportation.

Fix the machine on the trailer with following

method:
1. Fully extend the bucket and arm cylinder,

and then slowly lower down the boom.
CZ335-1104086
Fig.4-206

3. Stop the engine, and then remove the key

from the ignition switch.
4. Close all the doors, windows and covers.

Lock the cover, cap and door with locks.
CC13031403
Fig.4-207
5. Place the cushion block on both ends of the

track to prevent the machine from moving dur-
ing transportation, and fix the machine with
iron chains or wire ropes with proper strength.
In particular, fix the machine in a proper posi-

tion to ensure that it will not slip to the side.
CZ335-1103237
Fig.4-208

Rearview mirror
The rearview mirror is located in the position

B A
as shown in the right Figure.
If the rearview mirror is damaged or it shall be

reinstalled after removal for transportation,
the following method shall be adopted.
CZ335-1103142
Fig.4-209
Removal
1. Release the mounting bolt [2], and then re-

1
move the rearview mirror [1] from the support 2
[3].
2. Release the bolt [4], and remove the sup-

5
port [3] and clamp [5] from the handrail.
4 3
Installation
CZ335-1103239
1. Install the support [3] and clamp [5] onto the
handrail, and then tighten the bolt [4]. Fig.4-210
2. Install the rearview mirror [1] onto the sup-

port [3], and then tighten the mounting bolt [2].
• Make adjustment after installing the rear-
view mirror. For details, see the “Rearview
Mirror” on page 4-69.

4.4.3.4 Unloading
1. The machine can only be loaded and un-

loaded on a solid and flat ground. Keep a safe
distance from the roadside.
2. Apply a brake to the trailer and place a

cushion block [1] under the tyre to prevent the
trailer from moving. 2
• Place the left and right access boards [2] to
make them parallel to each other and equal 1
4
to the left and right spacing of the trailer 3
center [3]. The maximum installation Angle CZ335-1103229

[4] will be 15°. If the access board is bent
Fig.4-211
significantly under the weight of the ma-
chine, place a cushion block under the ac-
cess board.
3. Remove iron chains and wire ropes for fas-

tening the machine.
4. Start the engine, and fully warm it up.
5. Turn the safety lock control lever to the “UN-

LOCK” position.
CC13031404
6. Switch the traveling speed to the low speed
status by pressing down the function key of Fig.4-212
the display, and disable the automatic idle
speed.
WARNING
trailer, the automatic idle function shall be
canceled. If the automatic idle speed func-
tion is enabled, the speed of the engine will
change dramatically.
trailer, the traveling speed shall be kept in
the “Low Speed” mode. Do not switch the
traveling speed randomly.

7. Turn the fuel control knob to the [MIN] posi-

tion, and set the engine speed to low idle
speed. MA
X
MIN
CC13031401
Fig.4-213
8. Lift the work equipment, retract the arm

back to the lower part of the boom, and slowly
start the machine.
9. When driving the machine to the top of the

rear wheel of the trailer, stop it.
CZ335-1103242
Fig.4-214
NOTE：
• When unloading machine, the angle be-
tween the arm and the boom shall be
90~110°.
• The machine will be damaged if it is un-
loaded when the bucket is retracted. 90°-110°
• Do not insert the bucket into the ground and

the machine is driven onto the access board.
This will damage the hydraulic cylinder.
CZ335-1103243
Fig.4-215

10.When driving the machine onto the access

board, adjust the angle between the arm and
the boom to 90~110 °, lower down the bucket
to the ground, and slowly move the machine.
11.When driving the machine away from the

access board, slowly operate the boom and
the bucket, and drive down carefully until the
machine is completely away from the access
board.
CZ335-1103244
Fig.4-216
4.5 Lifting
WARNING
• Only the qualified and experienced operator holding official licensee (according to local law)
can operate the crane.
• Do not lift a machine when someone stands on the machine.
• Do not allow anyone to enter the lower or surrounding area of the lifted machine.
• Ensure that the wire rope used for lifting is strong enough to bear the weight of the machine. Do
not use damaged or aged cables or lifting tools.
• Do not lift the machine when the upper body turns to the side of the machine. Before lifting, ro-
tate the work equipment to one end of the sprocket and make the undercarriage parallel to the
longitudinal centerline of the upper structure.
• The safety lock control lever shall be turned to the locking position before lifting to prevent the
machine from accidentally moving.
• Keep the machine level during lifting.
• Do not lift the machine quickly. Otherwise, the lifting cable or lifting tool will be overloaded,
which may lead to fracture.
• Do not lift the machine with any other position except that provided in the following steps, or
use any of the lifting equipment except that provided in the following steps. Otherwise, the ma-
chine will lose its balance.
Wire rope selection

• The lifting procedure is applicable to the standard technical specification machine. For details of
machine weight, see the “Technical Specification” section of this manual.
• Select the suitable wire rope according to the weight of the excavator. Refer to the following
table.

Wire rope
(Ungalvanized standard “Z” twisted rope)
Nominal diameter of wire
Allowed load
rope
mm kN Ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
NOTE：
The allowed load value will be estimated by 1/6 or 1/7 of the fracture strength of the cable used.
NOTE：
The lifting method will be different according
to the actual accessories and options on the
machine. For proper lifting method, please
contact the authorized agent of SANY Heavy
Machinery.
Lift the machine on the flat ground through the

following methods
Standard specification machine
1. Start the engine, and then swing the upper

structure to locate the work equipment on the
side of the sprocket [1].
2. Fully extend the bucket cylinder and arm

1
cylinder, and then lower down the work equip-
ment to the ground with the boom cylinder, as
CZ335-1103245
Fig.4-217


4. Stop the engine, check whether there are

obstacles around the cab, and then leave the
machine. Close doors and windows of cab.
CC13031403
Fig.4-218
5. Make the wire rope cross through the part

between the first and second front supporting A
wheels and between the first and second rear

supporting wheels. The wire rope of the ma-
chine equipped with a roller guard shall cross
through the wire rope under the track.
6. Adjust the lifting angle of wire rope [A] to

30~40°, and then slowly lift the machine.
7. After the machine is lifted off the ground,

confirm that the hook condition and lifting con- CZ335-1103246
dition are normal, and then slowly lift the Fig.4-219

machine.
WARNING
• If the cable is too close to the hook, it will
slip off the hook and cause a serious acci-
dent. The middle part of the hook has the
maximum strength.
• Do not lift heavy objects when the suspen-
sion angle between the cable and the hook
is large. If the heavy object is lifted with
two or more cables, the strength of each
cable will be increased along with the in-
crease of the suspension angle.
• If lifting with a single wire rope, the load
may rotate during lifting, and the wire rope
may be released or slip from the winding
position and cause a dangerous accident.


SY500H Hydraulic Excavator Maintenance
Maintenance
5 Maintenance.......................................................................................................................5-1
5.1 Maintenance Guideline ........................................................................................................5-5
5.2 Treatment of Oil, Fuel and Coolant.....................................................................................5-7
5.2.1 Oil ..................................................................................................................................5-7
5.2.2 Fuel ...............................................................................................................................5-8
5.2.3 Coolant in the cooling system ...................................................................................5-9
5.2.4 Grease ..........................................................................................................................5-9
5.2.5 Storage of engine oil and fuel................................................................................. 5-10
5.2.6 Filter element ............................................................................................................ 5-10
5.3 Electrical System Maintenance........................................................................................ 5-10
5.4 Wear Parts ...........................................................................................................................5-11
5.5 Recommended Fuel, Coolant and Lubricating Oil ........................................................ 5-13
5.6 Tightening Torque .............................................................................................................. 5-16
5.7 Safety Critical Parts ........................................................................................................... 5-17
5.8 Maintenance Schedule...................................................................................................... 5-18
5.9 Maintenance Procedures.................................................................................................. 5-21
5.9.1 Initial 50-hour maintenance (after the first 50 hours only).................................. 5-21
5.9.2 Maintenance as demanded .................................................................................... 5-22
5.9.2.1 Checking and tightening track shoe bolts ..................................................... 5-22
5.9.2.2 Checking and adjusting track tension ............................................................ 5-23
5.9.2.3 Replacement of bucket .................................................................................... 5-26
5.9.2.4 Replacing bucket teeth (horizontal pin type) ................................................ 5-28
5.9.2.5 Adjusting bucket clearance ............................................................................. 5-30
5.9.2.6 Checking window washer fluid level and filling washer fluid ...................... 5-31
5.9.2.7 Checking and maintaining air conditioning ................................................... 5-32
5.9.2.8 Checking air springs......................................................................................... 5-34
5.9.3 Checks before startup ............................................................................................. 5-36
5.9.4 Maintenance after every 100 h............................................................................... 5-36
5.9.4.1 Lubricating work equipment ............................................................................ 5-36

Maintenance SY500H Hydraulic Excavator

5.9.5.1 Checking, cleaning and replacing air filter element ..................................... 5-39
5.9.5.2 Maintenance instructions of oil bath type air filter ........................................ 5-42
5.9.5.3 Checking and adjusting belt tension of HVAC compressor ........................ 5-45
5.9.5.4 Lubricating swing bearing................................................................................ 5-46
abnormal .................................................................................................... 5-46
5.9.6.1 General............................................................................................................... 5-47
5.9.6.2 Checking the level of grease in swing pinion and add grease ................... 5-47
5.9.6.3 Replacing the oil in engine oil pan, and replace the oil filter
element....................................................................................................... 5-48
5.9.6.4 Replacing fuel primary filter element.............................................................. 5-50
5.9.6.5 Replacing fuel secondary filter and fine filter element................................. 5-52
5.9.6.6 Cleaning and inspecting radiator and cooler fins ......................................... 5-55
5.9.6.7 Cleaning the ventilation/circulation filter of HVAC........................................ 5-56
5.9.6.8 Checking the oil level in swing gearbox and refilling ................................... 5-59
5.9.6.9 Checking the oil level of travel gearbox and refilling ................................... 5-60
5.9.6.10 Replacing hydraulic tank breather filter element........................................ 5-61
5.9.7 Maintenance after every 1000 h ............................................................................ 5-62
5.9.7.1 General............................................................................................................... 5-62
5.9.7.2 Replacing hydraulic oil filter element ............................................................. 5-62
5.9.7.3 Replacing the oil in swing gearbox................................................................. 5-64
5.9.7.4 Checking the cab door lock and the front window lock for
fastening..................................................................................................... 5-66
5.9.7.5 Checking the lubricating oil of cab door hinge and front window slide
guide and refill ........................................................................................... 5-67
5.9.7.6 Checking the rocker nut of wiper for looseness ........................................... 5-68
5.9.7.7 Checking all fastening parts of the engine exhaust pipe clamp ................. 5-68
5.9.7.8 Checking the fan belt tension and replace the fan belt ............................... 5-68
5.9.7.9 Checking the nitrogen pressure in accumulator (for hammer)................... 5-68
5.9.7.10 Adding grease into swing reducer................................................................ 5-68
5.9.8.1 General............................................................................................................... 5-69
5.9.8.2 Replacing the oil in final drive case ................................................................ 5-69
5.9.8.3 Cleaning hydraulic tank strainer ..................................................................... 5-70
5.9.8.4 Checking the nitrogen pressure in accumulator........................................... 5-71
5.9.8.5 Replacing the oil in hydraulic tank.................................................................. 5-74
5.9.8.6 Replacing the engine coolant and cleaning the inside of cooling
system ........................................................................................................ 5-76
5.9.8.7 Checking alternator .......................................................................................... 5-78
5.9.8.8 Checking and adjusting engine valve clearance.......................................... 5-78

5.9.9.1 General............................................................................................................... 5-78
5.9.9.2 Checking water pump ...................................................................................... 5-78
5.9.9.3 Checking starter motor..................................................................................... 5-78
5.9.9.4 Replacing accumulator .................................................................................... 5-79
5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber
for hardening ............................................................................................. 5-80
5.9.9.6 Checking the operation of compressor.......................................................... 5-80
5.9.10 Maintenance after every 8000 h .......................................................................... 5-80
5.9.10.1 General ............................................................................................................ 5-80
5.9.10.2 Replacing high pressure pipe clamp............................................................ 5-81
5.9.11 Maintenance after every 10000 h ........................................................................ 5-81

WARNING

5.Maintenance
5.1 Maintenance Guideline
Do not perform any inspection and maintenance not described in this manual.
Hour meter reading
Check the hour meter reading daily to determine whether maintenance must be performed.
Sany Heavy Machinery Co., Ltd. original wear parts
Use Sany Heavy Machinery Co., Ltd. original parts specified in the parts manual for replacement.
Sany Heavy Machinery Co., Ltd. original lubricating oil
Use Sany Heavy Machinery Co., Ltd. original engine oil and grease. Select the appropriate engine
oil and grease according to the ambient temperature.
Windshield washer fluid
When using the windshield washer fluid, pay attention not to allowing any dirt to enter the washer
fluid for fear of blockage of the nozzle and system.
Clean engine and lubricating oil
Use clean engine oil and grease. Keep the oil and grease containers clean and prevent foreign
matters from getting into such oil and grease.
Check drained oil and used filter element
After changing the oil or the filter element, check the used oil and filter element for metal chips and
foreign matters. If you find a lot of metal chips and foreign matters, report this to your supervisor
and take appropriate measures.
Fuel filter screen
If a fuel filter screen is provided at the fuel filler, do not remove the filter screen upon fueling.
Warning sign plate
Before maintaining the machine, hang a “Do Not Operate” sign or a similar warning sign on the
ignition switch or direction control to warn others that the machine is under maintenance. If neces-
sary, an additional warning decal can be attached around the hydraulic excavator.

Welding instructions
• Turn off the ignition switch for about one minute and then disconnect the negative (-) terminal of
the battery.
• Connect the grounding cable at more than 1 m away from the welding position. If the grounding
cable is connected to instruments, connectors, or other accessories, such meters will malfunc-
tion. If there is a seal or bearing between the welding position and the grounding point, the
grounding point shall be changed to keep away from such parts.
• Do not select the grounding point in the area around the work equipment pins or hydraulic
cylinders.
• Do not use voltages greater than 200 V continuously.
Prevent items from falling into the machine
• When opening the inspection hatch or the fuel tank filler for inspection, take care to prevent nuts,
bolts, or tools from falling into the machine. If they falls into the machine, they will damage the
machine and cause malfunctions and accidents. Therefore, such items shall be taken out imme-
diately after they falls into the machine.
• The items necessary for inspection can be put into your pockets only.
Dusty sites
When working in dusty sites, you shall follow these steps:

• When checking the machine or replacing the oil, stop the machine in a dust-free place to prevent
dust from entering the oil.
• Clean the filter element in a timely manner when the blocking alarm on the air filter gives an
alarm.
• Clean the radiator fins and other parts of the heat exchanger devices frequently and be careful
not to block such fins.
• Clean and replace the fuel filter frequently.
• Clean the electrical components, especially motors and alternators, to prevent dust
accumulation.
Avoid mixing lubricating oil
Do not mix different brands or grades of oil. If you need to add different brands or grades of oil,
drain the old oil and then replace it with new oil.
Lock inspection cover
When opening the inspection cover for maintenance, use the locking lever to firmly lock the cover
on the designated position. If the inspection or maintenance is performed without locking such cov-
er, the cover may suddenly close due to wind and cause personal injuries.

Hydraulic system bleeding
When the hydraulic equipment is repaired or replaced, or the hydraulic lines are disassembled and
installed, the air in the oil lines must be discharged.
Installation of hydraulic hoses
• When removing parts at the positions sealed with O-rings or gaskets, clean the mounting sur-
face and replace them with new ones. Be careful not to forget to install O-rings and gaskets.
• Do not twist or bend the hoses during installation. This will damage the hoses and significantly
shorten their service lives.
Inspection after inspection and maintenance
If the inspection is not performed after inspection and maintenance, an unexpected malfunction
may occur, resulting in serious injuries or damages. Be sure to follow the steps below:
• Check when operating the engine
• For details on checking when operating the engine, see “Maintenance during Running of the En-
gine” on the page 2-50, and be careful to ensure your safety.
• Check whether the inspected and maintained items are working properly.
• Check for oil leakage when the engine speed rises and the load is applied on the oil.
• Check after operation (with the engine turned off)
• Check whether you have forgotten any inspection or maintenance position.
• Check whether you have finished all inspection and maintenance items correctly.
• Check whether there is any tool or part that has fallen into the machine. It is very dangerous if
the part falls into the machine and snaps into the linkage mechanism.
• Check whether water or oil leakage occurs and whether all bolts are tightened.
Close engine hood tightly
When closing the engine hood after inspection and maintenance, hold the handle and lift the hood
slightly to check whether the lock tongue is firmly locked. If the engine hood is not locked, it may
open, thus causing dangers.
5.2 Treatment of Oil, Fuel and Coolant

5.2.1 Oil
• The oil in the engine and hydraulic equipment will continuously deteriorate in use due to ex-
tremely harsh working conditions (high temperature and pressure).
• Be sure to use the oil recommended in this manual and matching the highest and lowest ambi-
ent temperatures.
• The oil shall be changed within the specified oil change interval even if it is not dirty.

• As the blood in the human body, lubricating oil shall be treated with care to prevent foreign mat-
ters (water, metal particles or dust) from entering.
• Most of the machine’s failures are caused by the ingress of foreign matters. During storing or fill-
ing oil, special care shall be taken to prevent any foreign matter from getting into the oil.
• The oil shall be filled according to the specified amount of oil, otherwise it will cause abnormality.
• Do not mix different grades or brands of oil.
• If the oil in the work equipment is not clean, there is water in the oil, or the air gets into the oil
lines, contact your Sany Heavy Machinery Co., Ltd. authorized dealer.
• In order to check the condition of the machine, it is recommended that oil analysis shall be per-
formed regularly. If you need this service, please contact your Sany Heavy Machinery Co., Ltd.
authorized dealer.
• During oil change, be sure to replace related filter elements. When replacing the oil filter ele-
ment, remember to add the oil of the given specification to the new filter element before
installation.
• Please use the oil recommended by our company. Do not use unrecommended hydraulic oil be-
cause it may block the filter element once you use it.
• When changing the hydraulic oil, drain the residual oil in the lines and the cylinder as far as pos-
sible. It is allowed to mix a small amount of two types of oil.
5.2.2 Fuel
• Be sure to fill the fuel tank after the completion of daily work in order to prevent the condensation
of moisture in the air and the formation of water in the tank.
• The fuel injection pump is a precision part and it will not work properly if the fuel being used con-
tains any water or dirt.
• Drain the sediment and water from the fuel tank before starting the engine or 10 minutes after
refueling.
• Flush the fuel tank and the fuel system if there is any foreign matter in the fuel tank.
• If the engine has run out of fuel, or if the filter element has been replaced, the air in the lines
must be vented.
• Be sure to use the fuel specified in the “Operation and Maintenance Manual”. The fuel will solidi-
fy when it is used below the specified temperature (especially at temperatures below -15°C (5°
F)). When the fuel is used above the specified temperature, its viscosity will decrease and the
output power will drop.
• When storing the fuel or refueling, care shall be taken to prevent foreign matters from getting into
the fuel.

NOTICE
• Use diesel as the fuel.
• To ensure good fuel consumption and exhaust characteristics, the engine mounted on the ma-
chine uses a mechanically controlled high-pressure fuel injection device. This device requires
high-precision parts and lubrication, so its durability will be significantly reduced if you use low-
viscosity fuel with low lubricating capacity.
• Sulfur in the fuel will produce sulfur oxides during burning and react with water to become dilute
sulfuric acid, causing the engine damage. To prevent such failures, be sure to use the fuel con-
taining less than 0.2% of sulfur.
5.2.3 Coolant in the cooling system
• Coolant has important anti-corrosion and anti-freeze features. Even in areas not requiring anti-
freeze measures, it is essential to use antifreeze coolant.
Sany Heavy Machinery Co., Ltd. recommends the use of TEEC-L35 antifreeze with a concentra-
tion of 50% and without dilution. With excellent anti-corrosion, anti-freeze and cooling character-
istics, TEEC-L35 antifreeze can be used continuously for 1 year or 2000 hours.
• Sany Heavy Machinery Co., Ltd. does not recommend using any coolant other than TEEC-L35
antifreeze. If you use other coolant, it may cause serious problems such as corrosion of the en-
gine and cooling system parts made of light metals including aluminum.
If you use commercially available antifreeze as the coolant, be sure to keep its concentration fall
between 30% and 68% to ensure its corrosion resistance characteristic.
The mixing ratio of antifreeze and water is determined by the lowest ambient temperature, as
shown in the mixing table below.
Mixing ratio of water and antifreeze

Minimum ℃ -10 -15 -20 -25 -30 -35 -40
atmospheric
temperature ℉ 14 5 -4 -13 -22 -31 –40
Antifreeze volume ratio (%) 30 36 41 46 50 54 58
NOTE：
• Use distilled or tap water (soft water) when diluting the anti-freeze coolant.
• Natural water, such as river and well water (hard water), contains a lot of minerals (calcium and
magnesium), which are easy to form fouling inside the engine and the radiator. The fouling
formed inside the engine or the radiator will be difficult to be removed. Poor heat exchange may
also cause overheating.
5.2.4 Grease
• Grease is used to prevent twisting at the connections and noise.

• Fill grease if any part becomes inflexible or produces noise after used for a long time.
• Be sure to use the recommended grease, and select grease in accordance with the replacement
cycle and ambient temperature recommended in this manual.
• When filling grease, wipe away the old grease that has been squeezed out. Be sure to wipe
away the old grease that has been stained with sand and dirt, otherwise it will cause wear of the
rotating parts.
5.2.5 Storage of engine oil and fuel
• Place them indoors to prevent water, dust, or other debris from getting into them.
• When storing the oil drums for a long time, place the drums side so that the fillers of the drums
are on the side (to prevent inhalation of moisture). If the oil drums have to be placed outdoors,
cover them with tarpaulins or take other protective measures.
• In order to prevent the oil or fuel from deteriorating during long-term storage, it must be used in
the order of first-in and first-out (namely the lubricating oil or fuel stored for longer time is used
first).
5.2.6 Filter element
• The filter element is an extremely important safety component that prevents foreign matters in
the oil and air lines from getting into important devices and causing malfunctions. Replace all fil-
ter elements regularly. When used under harsh conditions, the filter element shall be replaced
within a short period based on the sulfur content in all lubricating oil and fuel.
• Do not reuse cleaned filter element but replace it with a new one.
• Check whether metal particles are adsorbed on the old filter element when replacing it. If you
found metal particles, please contact your Sany Heavy Machinery Co., Ltd. authorized dealer.
• Do not unpack the spare filter elements before use.
• Use Sany Heavy Machinery Co., Ltd. original filter elements.
5.3 Electrical System Maintenance
• Wet electrical equipment or damaged wire claddings will cause electrical short circuits and ma-
chine malfunctions. Do not flush the cab with water. When rinsing the machine, take care to pre-
vent water from getting into the electrical components.
• Electrical system maintenance includes checking the fan belt tension and checking the fan belt
for damage and wear.
• Do not install any electrical component other than those specified by Sany Heavy Machinery
Co., Ltd.
• External electromagnetic interference may cause malfunction of the controller in the control sys-
tem. Contact your Sany Heavy Machinery Co., Ltd. authorized dealer when you install radio re-
ceivers or other wireless devices.
• When working on a beach, carefully clean the electrical system to prevent corrosion.

• When installing the electrical equipment, connect it to a dedicated power connector. Do not con-
nect the optional power supply to the fuse, starter switch or battery relay.
5.4 Wear Parts
• Wear parts (such as filter elements, and bucket teeth) shall be replaced during regular mainte-
nance or before reaching their wear limits.
• In order to use the machine economically, wear parts shall be replaced correctly.
• High-quality Sany Heavy Machinery Co., Ltd. original parts shall be used for replacement.
• When ordering such parts, check the part numbers in the part manual.

Table of Wear Parts
Item Part No. Part name Quantity Replacement Interval

Engine oil
filter B222100000494 Filter element 2 Every 500 h
element
Fuel coarse
60241429 Filter element 1 Every 500 h
filter
Fuel fine 60151839 Filter element 2
Every 500 h
filter 60250941 Filter element 2
B222100000640 Safety filter element 1
Air filter Purging for 6 times or 1
element Primary filter year
B222100000641 1
element
Pilot filter
A222100000119 Filter element 1 Every 1000 h
element
Breather
valve filter 60129666 Filter element 1 Every 500 h
element
Oil suction filter
60251436 1
element
Hydraulic oil
60014121 Return filter element 1 Every 1000 h
filter
Drainage filter
60210416 1
element
Air 60250669 Fresh air filter 1
conditioning Every half year
B222100000711 Recirculation filter 1
filter
60257045 Bucket teeth 4
60257046 Pin 4
4-tooth rock 60257047 Snap ring 4
bucket 12827269 Side teeth 2 —
(standard) A210110000424 Bolt 10
A210402000048 Washer 10
A210307000078 Nut 10
60265885 Bucket teeth 5
60266484 Pin 5
5-tooth rock 60266485 Snap ring 5
bucket 12827269 Side teeth 2 —
(optional) A210110000424 Bolt 10
A210402000048 Washer 10
A210307000078 Nut 10

5.5 Recommended Fuel, Coolant and Lubricating Oil
• Unless otherwise specified, the machine is filled with the oil and coolant listed in the table below
when it is shipped from the factory.
Item Model
Engine oil pan Diesel engine oil Caltex CI-4 15W-40
Swing mechanism box
Gear oil 85W/140
Final gearbox
Hydraulic oil system Caltex anti-wear hydraulic oil HDZ46
Radiator TEEC-L35 Antifreeze
• In order to keep the best condition of the machine for a long time, it is essential to follow the oil
operation and maintenance instructions in this manual. Failure to do so may result in excessive
wear of the engine, drive system, cooling system, and other parts, thus shortening their service
lives.
• Commercially available lubricating oil additives may cause damage to the machine. Sany Heavy
Machinery Co., Ltd. does not recommend any lubricating oil additive.
• The specified capacity means the total amount of oil in the tank and lines. The adding capacity
means the amount of oil that needs to be added to the system during inspection and
maintenance.
• When starting the engine at temperatures below 0°C (32°F), be sure to use the recommended
multi-grade oil even if the ambient temperature is high in the daytime.
• Use the recommended oil according to the ambient temperature in the table below.
Environmental temperature
12- Recom-
Or Fluid -22 -4 -14 32 50 68 86 104
2℉ mended
system type
5- oil fluid
-30 -20 -10 0 10 20 30 40
0℃
5W-30
5W-40
Engine Engine
oil pan oil
10W-30
15W-
40（note）

Environmental temperature
12- Recom-
Or Fluid -22 -4 -14 32 50 68 86 104
2℉ mended
system type
5- oil fluid
-30 -20 -10 0 10 20 30 40
0℃
40
HDZ32-Ⅱ
(ISO
Hydraulic Hydraulic VG32)
system oil HDZ46-Ⅱ
(ISO
VG46)
-No. 30
diesel
-No. 10
Fuel tank Diesel
light diesel
No. 0 light
diesel
TEEC-L35
Radiator Coolant
Antifreeze
NOTE：
The HTHS (high temperature high shear viscosity at 150°C) specified by ASTMD4741 must be no
less than 3.5 mPa-S, and the engine oil 15W-40 recommended by Sany Heavy Machinery Co.,
Ltd. is the most suitable.
Recommended oil:
1. Engine oil
Select and use the oil with a suitable viscosity grade according to the specified air temperature
range during oil change.
Engine oil grade: above APICI-4
Name and brand of recommended engine oil: Caltex CI-4 15W-40 engine oil.
2. Engine fuel
Light diesel (GB252-2011)

CAUTION
• Use low sulfur fuel with a cloud point of at least 10°C below the minimum desired fuel tempera-
ture. Cloud point means the temperature at which the waxy crystals in the diesel begin to form.
• Commercially available grades of diesel used shall have the sulfur content of less than 350mg/
kg.
• Keep the fuel clean and free of moisture or foreign matters when refueling.
3. Hydraulic oil
The hydraulic system uses Caltex anti-wear hydraulic oil HDZ46 (code: B420106000036).
CAUTION
When operating at low ambient temperatures below 0°C, the following temperature-raising
operations must be performed to ensure the safety of the hydraulic system:
• Start the engine and let it idle for 7 to 10 minutes and then increase the speed to 1000 to 1200
r/min. Do not perform any operation on the excavator, and allow it to run for 30 to 40 minutes or
more under no load in order to increase the hydraulic oil temperature to 20 °C or more.
• After the above temperature-raising operations are completed, normal construction works can
be performed, and the temperature-raising time shall be appropriately adjusted according to
the ambient temperature. When normal construction works start, the handle and the foot valve
shall be slowly operated, and close attention shall be paid to the operation conditions of the sys-
tem. Working at the hydraulic oil temperature below 20 ° C may damage the hydraulic
components.
• Select the appropriate hydraulic oil according to the working area where the machine is located.
Before the machine leaves the factory, our company is responsible for filling the appropriate
brand of hydraulic oil. After the machine leaves the factory, the user is responsible for changing
the oil. The user may consult our company’s after-sales service personnel to obtain the cor-
rect hydraulic oil specifications and brands.
Capacity table
Swing
Specified Engine oil Final Hydraulic Cooling Fuel
mechanism
capacity pan gearbox system system tank
box
L 50 14 2×10 400 60 680
SY485H US
13.2 3.7 2×2.6 105.7 15.9 179.6
gal

5.6 Tightening Torque
CAUTION
• If the nuts, bolts, or other parts are not tightened to the specified torques, the tightened parts
may become loose or damaged, causing the machine faults or problems during operation.
• Be careful when tightening the parts.
Unless otherwise specified, the metric nuts and bolts shall be tightened to the torques shown in
the table below.
If the bolts or nuts need to be replaced, they shall be replaced with the same sizes of Sany Heavy
Machinery Co., Ltd. original parts.
Table of Tightening Torques

Bolt Torque (N·m)
No.
Specification Grade 10.9 Grade 12.9
1 M6 13.2±1.4 16.2±1.6
2 M8 31±3 38.7±4
3 M10 66±7 78±7
4 M12 113±10 137±10
5 M14 177±19 210±20
6 M16 279±30 339±30
7 M18 382±39 450±40
8 M20 549±59 664±59
9 M22 697±70 864±85
10 M24 927±103 1100±100
11 M27 1320±140 1683±150
12 M30 1785±170 2200±200
13 M33 2295±200 2900±280
14 M42 4700±450 5985±590
15 M48 7140±650 9100±900
• Use the following table for hydraulic hoses

Hose
Nut Torque (N·m) Joint Torque (N·m)
M14 24.5±5 M14 34.3±5
M18 51±8 M16 54±5
M22 74±14 M18 70±10
M26 105±20 M20 93±10
M30 135±20 M22 125±10
M36 166±26 M24 142±20
M42 240±30 M26 180±20
(Pipe) Joint
Metric Torque (N·m) British Torque (N·m)
M14 24.5±5 G1/8″ 16.7±2
M16 45±7 G1/4″ 36.7±2.5
M18 51±8 G3/8″ 73.5±5
M20 58±8 G1/2″ 107.8±7.8
M22 74±14 G3/4″ 161.7±14.7
M24 74±14 G1″ 220±25
M26 105±20
Plug
Metric Torque (N·m) British Torque (N·m)
M20 49±5 G3/8 68.6±20
M24 68.6±10
Nozzle
British Torque (N·m)
G3/4（A） 161.7±14.7
5.7 Safety Critical Parts

When operating or driving the machine, the user must regularly maintain the machine in order to
always ensure safety. In addition, in order to further improve safety, the user shall periodically re-
place the parts listed in the table. These parts are closely related to safety and fire protection.
As the materials of safety critical parts will become aged or deteriorated over time, it is difficult to
judge if such parts are normal through regular maintenance and visual inspection. Therefore, they
shall be replaced regardless of their conditions once the specified time expires. This can effectively
guarantee the functions of these parts.
The safety critical parts, if have any abnormality before the end of their replacement cycles, must
be repaired or replaced immediately.

If the hoses clips are deteriorated (such as deformation or cracks), they shall be replaced together
with the hoses.
O-rings, gaskets, and other similar parts must be replaced while you replace the hoses.
Contact your Sany Heavy Machinery Co., Ltd. authorized dealer to replace the safety critical parts.
List of Safety Critical Parts

Regular Replacement of Safety Critical
No. Quantity Replacement Cycle
Parts
1 Fuel hose (engine - fine filter - engine) 2
2 Fuel hoses (fuel tank - water separator) 1
3 Fuel hoses (oil-water separator - fuel primary 1
filter)
4 Fuel return hoses (engine - fuel tank) 2
5 Fuel hoses (fuel primary filter - engine) 1
6 Pump outlet hoses (pump - control valve) 2
7 Work equipment hoses (boom cylinder inlet) 4
8 Work equipment hoses (bucket cylinder line - 2 Every 2 years or 4000
boom root) hours
9 Work equipment hoses (bucket cylinder inlet) 2 (whichever occurs
first)
10 Work equipment hoses (arm cylinder line - 2
boom root)
11 Work equipment hoses (arm cylinder inlet) 2
12 Swing line hoses (swing motor inlet) 2
13 Main suction hoses 1
14 Travel line hoses (control valve - swivel joint) 4
15 Travel line hoses (swivel joint - travel motor) 4
16 Pump pressure hoses 1
17 Accumulator (for oil line control) 1
18 High pressure line clamp 1
Every 8000 h
19 Anti-fuel injection cover 1
20 Seat belt 1 Every 3 years
5.8 Maintenance Schedule

The standard calendar time or operation time is used as inspection and maintenance time, which-
ever occurs first.

If the machine is equipped with a hydraulic breaker, the maintenance schedule for some parts may
vary. See “Replacing Hydraulic Oil and Hydraulic Oil Tank Filter” on the page 7-13 for details.

Maintenance Schedule
Initial 50-hour maintenance (after the first 50 hours only)
Maintenance as demanded
Checking and tightening track shoe bolts .................................................................................. 5-22
Checking and adjusting track tension ........................................................................................ 5-23
Replacement of bucket .............................................................................................................. 5-26
Replacing bucket teeth (horizontal pin type).............................................................................. 5-28
Adjusting bucket clearance ........................................................................................................ 5-30
Checking and maintaining air conditioning ................................................................................ 5-32
Checking air springs................................................................................................................... 5-34
on page 5-36
Maintenance after every 100 h
Lubricating work equipment ....................................................................................................... 5-36
Checking, cleaning and replacing air filter element ................................................................... 5-39
Maintenance instructions of oil bath type air filter...................................................................... 5-42
Checking and adjusting belt tension of HVAC compressor ....................................................... 5-45
Lubricating swing bearing .......................................................................................................... 5-46
Checking whether pipe clamps and collars of the hydraulic system are abnormal................... 5-46
Checking the level of grease in swing pinion and add grease................................................... 5-47
Replacing the oil in engine oil pan, and replace the oil filter element ........................................ 5-48
Replacing fuel primary filter element ......................................................................................... 5-50
Replacing fuel secondary filter and fine filter element ............................................................... 5-52
Cleaning and inspecting radiator and cooler fins....................................................................... 5-55
Cleaning the ventilation/circulation filter of HVAC ..................................................................... 5-56
Checking the oil level in swing gearbox and refilling ................................................................. 5-59
Checking the oil level of travel gearbox and refilling.................................................................. 5-60
Replacing hydraulic tank breather filter element ....................................................................... 5-61
Replacing hydraulic oil filter element ......................................................................................... 5-62
Replacing the oil in swing gearbox ............................................................................................ 5-64
Checking the cab door lock and the front window lock for fastening......................................... 5-66
Checking the lubricating oil of cab door hinge and front window slide guide and refill.............. 5-67

Checking the rocker nut of wiper for looseness......................................................................... 5-68

Checking all fastening parts of the engine exhaust pipe clamp................................................. 5-68
Checking the fan belt tension and replace the fan belt.............................................................. 5-68
Checking the nitrogen pressure in accumulator (for hammer) .................................................. 5-68
Adding grease into swing reducer.............................................................................................. 5-68
Replacing the oil in final drive case............................................................................................ 5-69
Cleaning hydraulic tank strainer ................................................................................................ 5-70
Checking the nitrogen pressure in accumulator ........................................................................ 5-71
Replacing the oil in hydraulic tank ............................................................................................. 5-74
Replacing the engine coolant and cleaning the inside of cooling system ................................. 5-76
Checking alternator.................................................................................................................... 5-78
Checking and adjusting engine valve clearance ....................................................................... 5-78
Checking water pump ................................................................................................................ 5-78
Checking starter motor............................................................................................................... 5-78
Replacing accumulator .............................................................................................................. 5-79
Checking the high pressure pipe clamp for looseness, and the rubber for hardening .............. 5-80
Checking the operation of compressor ...................................................................................... 5-80
Replacing high pressure pipe clamp.......................................................................................... 5-81
5.9 Maintenance Procedures

5.9.1 Initial 50-hour maintenance (after the first 50 hours only)
• Replace the engine oil and the oil filter ele-

ment. For details on the replacement or
maintenance method, see the “Mainte-
nance after Every 500 Hours” section.

5.9.2 Maintenance as demanded
5.9.2.1 Checking and tightening track shoe bolts
If the machine is used with the loose track

shoe bolts [1], you must tighten the loose bolts
immediately because they will break.
Tighten
Three-rib track shoes
1. Tighten them to the torque of 800-900 N.m

firstly.
2. Then check if the nuts and track shoes are

CZ335-1104014
in close contact with the link faces.
Fig.5-1
3. After inspection, tighten them by 45° again.
4. Finally tighten them to the torque of 1320-

1418N.m.
Tightening sequence
Tighten the bolts in the order shown on the

right figure. After tightening, check whether
the mating surfaces between the nuts and the
track shoes and the links are in close contact.
1 3
4 2
CZ335-1104015
Fig.5-2

5.9.2.2 Checking and adjusting track tension
The wear of the pins and their bushings on

the lower body part varies with the work condi-
tions and soil types. Therefore, the track ten-
sion shall always be checked to maintain the 2
standard tension. a
Stop the machine on a flat, solid ground to

check and adjust the track shoes.
Inspection
1
1. Start the engine and operate it at an idle
CZ335-1104016
speed and then move the machine forward a
Fig.5-3
distance. This distance is equivalent to the
length of the tracks on the ground. Then stop
the machine slowly.
2. Select a straight stick and place it over the

track shoes above the idler [1] and the carrier
roller [2] (see the right figure).
3. Measure the maximum distance “a” (sag)

between the upper surface of the track and
the bottom surface of the stick.
The standard value of “a” should be: 10 to 30

mm (0.4 to 1.2 in)
Adjustment
If the track tension is not standard, adjust it as

follows.
CZ335-1102081
Fig.5-4

WARNING
• If the specified maintenance procedures
are not followed during the adjustment of
the track tension, the grease drain plug
may fly off, causing serious injuries or even
deaths.
• When adjusting the track tension, keep
your face, hands, feet, or other parts of
your body away from the front of the
grease drain plug.
Increase track tension
WARNING
• Never loosen the grease drain plug when
you increase the track tension. Otherwise,
this may cause serious injuries or deaths.
CZ335-1102080
Fig.5-5
Prepare a grease gun when increasing the

tension.
1
1. Use the grease gun to fill grease through
2
the grease fitting [2]. (The grease fitting [2] is
combined with the grease drain plug [1].)
2. To check if the track tension is proper,

slowly move the machine 7 to 8m (23ft-26ft
3in) forward and then stop it slowly.
CZ335-1104020
3. Check the track tension again. Readjust it if
the tension is inappropriate. Fig.5-6

4. Continue to fill grease until the size [S] is

zero. If the tension is still loose, this shows the
pins and their bushings are worn excessively.
You must reverse or replace them. Contact
your Sany Heavy Machinery Co., Ltd. author-
ized dealer for repairs.
Fig.5-7
Loose track tension
WARNING
• Do not loosen the grease drain plug more
than one turn because it may fly off under
high pressure conditions.
• Do not loosen any part other than the
grease drain plug.
Prepare a long socket wrench when loosening CZ335-1102080
the tension.
Fig.5-8
1. Use the long socket wrench to slowly rotate

the grease drain plug [1] counterclockwise to
release grease. The grease will be discharged 1
from the grease fitting [2]. 2
You can only loosen the plug [1] one turn at

most.
2. If the grease cannot be drained smoothly,

you may move the machine a short distance
forward and backward.
CZ335-1104020
3. After obtaining a proper track sag, tighten
the plug [1] clockwise. Fig.5-9
To check if the tension is appropriate, run the

engine at an idle speed, slowly move the ma-
chine forward (the distance is equivalent to
the length of the track shoe on the ground)
and then stop it.
4. Check the track tension again. Readjust it if

the tension is inappropriate.
NOTE：
• Gravel or soil between the chain wheels and
the track chains shall be removed before
loosening of the tracks.
• If the track tension cannot be loosened as
described above, contact your Sany Heavy
Machinery Co., Ltd. authorized dealer for
repairs.
5.9.2.3 Replacement of bucket
CAUTION
• When you knock on the pins with a ham-
mer, metal fragments may fly off and cause
serious injuries. You must wear goggles,
safety helmets, protective gloves, and oth-
er protective equipment when performing
such operation.
• The pins, if knocked forcedly, may fly off
and injure people surrounding them. Be-
fore starting such operation, make sure
that there are no other persons in the sur-
rounding area.
• Do not stand behind the bucket when dis-
assembling the pins. Be careful not to
place your feet under the bucket when
working at one side.
• When removing or installing the pins, be
careful not to get your fingers caught.
• When aligning the pin holes, do not insert
your fingers into the holes.

1. Stop the machine on a solid, level ground.

Gently lower the bucket to a position just in
contact with the ground.
If you lower the bucket to the ground with ex-

cessive force, the resistance will increase at
the pins, which will not be easily removed.
CZ335-1103207
Fig.5-10
2. Remove the double nuts on the arm pin [A]

and the link pin [B], remove the bolts, pull out
the arm pin [A] and the link pin [B], and finally
remove the bucket.
NOTE：
• After removing the pins, make sure not to get
mud or sand on the pins.
• Take care not to damage the dust seals and
wear rings installed on both ends of the
bushings.
Fig.5-11
3. Align the arm with the hole [1] of the re-

placed bucket and the link with the hole [2].
1
Then insert the greased pins [A] and [B] into
the holes [1] and [2] respectively. 2
WARNING
• When performing connection works, ap-
point a commander and follow his com-
mands and instructions.
CZ335-1103202
Fig.5-12

NOTE：
When installing the bucket, for the arm pin po-
sition [A], put the bucket O-ring [3] into the po-
sition shown in the right figure. After inserting
the pins, install them into standard slots.
4. Install the retaining plate bolts and nuts for

all pins and then fill grease to such pins.
NOTE：
• Lubricate them thoroughly with grease until
grease is squeezed out of the end faces. Fig.5-13
• The dust seals, if damaged, shall be re-
placed while you replace the bucket. If the
damaged seals are used, sand or dust may
enter the pins, causing their abnormal wear.
5.9.2.4 Replacing bucket teeth (horizontal pin type)
Replace the bucket teeth before the bucket

teeth base is worn.
WARNING
• Before replacing the bucket teeth, keep the
work equipment in a stable state, turn off
the engine and lock all travel levers se-
curely. Otherwise, this may cause danger
due to misoperation.
• If you knock out the lock pin with excessive
force, there is a danger that the pin will fly
off. Check and make sure that there is no
person in the surrounding area.
• You must wear safety glasses, gloves and
other protective equipment because frag-
ments may fly off during replacement.

1. Place a block at the bottom of the bucket

(as shown on the right figure) to remove the
bucket teeth pins and keep the bottom of the
bucket level.
CZ335-1104023
Fig.5-14
2. Check and make sure that the work equip-

ment is in a stable state and then place the
safety lock lever on the “lock” position.
CC13031403
Fig.5-15
3. Place a metal rod on the top of the pin [1],

knock the rod with a hammer to knock the pin
[1] out and remove the bucket teeth [2].
2
NOTE：
1
• Use a metal rod slightly smaller in diameter
than the pin.
• If you cannot safely remove the bucket teeth
with this method, contact your Sany Heavy
Machinery Co., Ltd. authorized dealer for
replacement. CZ335-1104025
Fig.5-16

4. Remove the tooth bushings and check the

lock pin for any damage. Replace it if neces-
sary. Worn lock pins and bucket teeth must be
replaced with new ones. 2
5. Clean the mounting surface, put the clip

spring into the mounting hole of the tooth base
and then put the new bucket teeth [2] into the
tooth base, push the pin [1] into the part by
hand, and then use a hammer to knock in the 1
pin to lock the bucket teeth onto the tooth CZ335-1104026
base.
Fig.5-17
5.9.2.5 Adjusting bucket clearance
WARNING
• When adjusting the clearance, keep the
work equipment in a stable state, turn off
the engine and lock all travel levers se-
curely. Otherwise, this may cause danger
due to misoperation.
After the machine is used for a period of time,

the connection clearance of the bucket must
be properly adjusted. When the connection
clearance is too large or too small, you need
to install or remove the adjusting shims.
1. Stop the machine on a level ground. Lower

the bucket to the ground. The location where
the work equipment is placed is shown in the
right figure.
2. Run the engine at an idle speed. Secure

the bucket on the ground and slowly rotate it
counterclockwise until the left inner end of the
bucket is in close contact with the left end face
of the arm.
3. Turn off the engine and pull the safety lock CZ335-1103207
lever to the “lock” position.

Fig.5-18

4. Move the O-ring [1] and accurately measure

the clearance “a” with a feeler gauge.
5. Unscrew the 2 bolts [3], washers [4] and the

pressure plates [2] and knock out the pin [5] to
disconnect the bucket [6] and the arm [8].
6. Add the washers [7] based on actual wear

conditions so that the clearance is less than
the thickness of one washer.
7. Knock the pin [5] back to its original posi-

Fig.5-19
tion, and then install the pressure plates [2],
the washers [4] and the bolts [3] to their origi-
nal positions.
5.9.2.6 Checking window washer fluid level and filling washer fluid
During each routine maintenance of the ma-

chine, check and fill the washer fluid and
check the working condition of the washer by
turning on its switch.
When the washer fluid is insufficient, the

ejected washer fluid will contain bubbles.
When this occurs, check the fluid level in the
reservoir (located in the access door on the
left side of the machine). Fill the washer fluid if
CZ335-1104030
needed.
Fig.5-20
1. Open the access door on the left side of the
machine and then you can see the reservoir;
2. Open the cover of the reservoir, fill the

washer fluid, and then close the cover tightly;
3. Turn on the washer switch to check if the

spray is normal.
NOTE：
When filling the washer fluid, be careful to pre-
vent dust from getting into the fluid.
Mixing ratio of pure washer fluid to water
Select the mixing ratio according to the ambi-

ent temperature. Before filling, dilute the

washer fluid with water at the ratio shown in

the table below.
Mixing
Ratio of
Operating Anti-freeze
Washer
Area Temperature
Fluid to
Water
- 10℃（14
General 1:2
°F）
Winters in - 20℃（- 4
1:1
cold areas °F）
Winters in Pure
- 30℃（- 22
extremely washer
°F）
cold areas fluid
NOTE：
There are two kinds of washer fluid used at
-10°C (14°F) (common) and -30°C (-22°F) (in
cold areas), depending on the operation areas
and seasons.
5.9.2.7 Checking and maintaining air conditioning
Check the refrigerant (gas) level
WARNING
• Do not touch the refrigerant because it will
cause blindness or frostbite after getting in-
to your eyes or dipping on your hands. Do
not loosen any part of the refrigerant line.
• Keep any open fire away from the position
where the refrigerant gas leaks.

The refrigeration performance of the air condi-

tioner will be poor if the refrigerant (R134a) is
not sufficient. When the air conditioner is op-
erated with insufficient refrigerant, the com-
pressor may be damaged.
When the engine idles at a high speed and

the air conditioner is in a state of maximum re-
frigeration, observe the inspection window [2]
on the condenser reservoir [1] and check the
situation of the refrigerant flowing into the re-
frigerant lines.
Fig.5-21
• The refrigerant flows and there is no bub-

ble: it is appropriate
• The refrigerant flows and there are bubbles
(continuous passage of bubbles): it is
insufficient
• The lines are colorless and transparent:
there is no refrigerant
NOTE：
In the case of insufficient refrigerant, contact
your Sany Heavy Machinery Co., Ltd. author-
ized dealer to fill the refrigerant. Fig.5-22
Inspection under unused circumstance
When the machine is not used for a long time,

it is necessary to operate the air conditioner
for 3 to 5 minutes once every month and lubri-
cate various parts of the compressor.
Table of Inspection and Maintenance Items of Air Conditioning Equipment

Inspection and
Content Maintenance Period
Maintenance Item
Twice a year, in spring and
Filling amount
autumn respectively
Refrigerant (gas)
Leakage at the line connections and
Daily
inside the parts
Condenser Clogging of radiator fin Every 500 h
Compressor Function Every 4000 h
V-type belt Loosing and bending Every 250 h

Deterioration, wear, scratch and

Every 250 h
crack
Noise, odor, or abnormal heating When necessary
Fan motor and fan Function (check for abnormal noise) When necessary
Air conditioning volume Air volume switch control and
Daily
switch switching function
Function (check whether the
Control mechanism When necessary
function is normal)
Loosing at the connections, and
Connecting bolt Half a year
loosing or falling off of nuts or bolts
Installation situation, whether the
connection positions are loose and
Connecting line When necessary
whether there is any leakage or
damage
Receiver-drier temperature The temperature difference
One year
difference indicates that the dryer is clogged
5.9.2.8 Checking air springs
WARNING
• The air springs are filled with high-pressure
nitrogen. Improper operation may cause
explosion, resulting in damage to the ma-
chine and personal casualties.
• Keep away from fire.
• Do not punch or weld them.
• Do not knock them to avoid any impact.
The air springs are located on the top of the

cab (at the left and right).
In the following cases, contact your Sany

Heavy Machinery Co., Ltd. authorized dealer
for inspection, repair and replacement.
• When the top window of the cab cannot be
easily opened.
• When the top window of the cab cannot be
kept open.
• When oil or gas leakage of the air springs is CZ335-1104036
found.
Fig.5-23

The method for release of internal pressure of

hydraulic oil lines
WARNING
• When checking or replacing the fittings or
the hoses, release the pressure in the hy-
draulic oil lines because they are always
under pressure. If the pressure is not re-
leased, high pressure oil will be ejected
and cause serious personal injuries.
• After the engine is turned off, the parts and
oil are still at high temperatures, which
may cause burns. Be sure to wait for cool-
ing down and then start the operation.
• When the filler cap is removed, the oil will
be ejected. Therefore, you shall slowly turn
the cap to release the internal pressure be-
fore removing the cap.
1. Stop the machine on a level and solid

ground.
CZ335-1103207
Fig.5-24

2. Within 15 seconds after stopping, turn the

ignition switch to the [ON] position, pull up the
safety lock lever to the “UNLOCK” position,
and fully operate the travel lever and the oper-
ating handle in all directions to release the
pressure of the pilot oil lines.
3. Unscrew the butterfly nut [1] of the breather

valve on the hydraulic oil tank, and then press
the exhaust button to release the internal
pressure of the hydraulic oil tank.
Fig.5-25
5.9.3 Checks before startup
For details on the following items, see “Checks before startup” in the operation manual.
• Drain water and sediments from the fuel tank

• Check the oil-water separator for water and sediments and drain water
• Check the level of oil in the hydraulic oil tank and fill oil
• Check the coolant level and fill the coolant
• Check the level of oil in the engine oil pan and fill oil
• Check the wires
• Check the fuel level and refuel
• Check the work light switch
• Check the function of the horn
• Check and keep the exhaust pipe under the engine smooth (under soil working conditions,
check it at any time during working)
5.9.4 Maintenance after every 100 h
5.9.4.1 Lubricating work equipment
CAUTION
• If there is abnormal noise at the lubrication positions, perform other lubrication in addition to the
lubrication during maintenance period.
• After excavating in water, lubricate the pins that are immersed in water.
1. Set the work equipment to the lubrication positions shown in the figure below, and then lower the
work equipment to the ground and shut off the engine.
2. Use a grease gun to fill grease through the lubrication positions shown in the figure below.

3. After filling the grease, wipe off the old grease that has been squeezed out.
2,3,4 1
6 5
7 8 9 10,11 12
CZ335-1104046
Fig.5-26
1. Boom cylinder root pins (2 positions)
CZ425-1104015
Fig.5-27
2. Boom foot pins (2 positions)
Fig.5-28

3. Boom cylinder piston rod end (2 positions)
4. Arm cylinder root pin (1 position)
Fig.5-29
5. Boom-arm connecting pin (1 position)
6. Arm cylinder piston rod end (1 position)
7. Bucket cylinder root pin (1 position)
Fig.5-30
8. Arm-link connecting pin (1 position)
9. Arm-bucket connecting pins (2 positions)
Fig.5-31

10.Link connecting pins (2 positions)
11.Bucket cylinder piston rod end (1 position)
12.Bucket-link connecting pin (1 position)
Fig.5-32
5.9.5.1 Checking, cleaning and replacing air filter element
CAUTION
• If you carry out checking, cleaning or re-
placement while the engine is running,
dust may get into the engine and cause
damage to it. Be sure to shut off the engine
before performing these operations.
• Be sure to keep close matching between
the sealing rubber of the end cover and the
filter.
• Never take out the inner filter element for
cleaning. This will get dust in and cause
the engine failures.
• The inner and outer filter elements must be
replaced at the same time.
• Wear goggles, dust masks or other protec-
tive devices when cleaning with com-
pressed air.
• Do not forcibly pull out the outer filter ele-
ment. When working at a high place or a
place where footholds are unstable, be
careful not to drop the outer filter element
under the reaction force when pulling it
out.

Cleaning and replacement of outer filter

element
• Cleaning: when hearing the air filter block-
ing alarm or every 250 h.
• Replacement: cleaning for 6 times or every
1 year (whichever comes first).
1. Open the door at the radiator side (left rear)

of the machine, remove the clip (or clamp) [1],
and then remove the cover [2]. T O P
×××××××××××××××××××××××××××××
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2
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×××××××××××××××××××××××××
××××××××××××××××××××××
××××××××××××××××××
0-13017
Fig.5-33
2. Hold the outer filter element [3], gently

shake it up and down and left and right, and
turn the filter element left and right to pull it
out. 4
3. Check if the inner filter element [4] is shifted

3
or tilted. If it is tilted, put it correctly by hand. 5
4. Use a clean cloth to cover the inner filter el-

ement [4] to prevent dust from getting into.
5. Clean the dust on the cover and inside the

CZ335-1104006
air filter housing [5].
Fig.5-34

6. Purge with compressed air of 0.2 MPa or

less along the wrinkles at the inner and outer
sides of the primary element. Never blow with
compressed air from outside to inside.
NOTE：
• Do not knock the filter element with any ob-
ject when cleaning it.
• The filter paper, filter element, and seal ring,
CZ335-1104008
if damaged, cannot be used.
• If you have used the filter element or O-ring Fig.5-35
for one year, do not use them again after
cleaning them because their reuse will cause
malfunctions.
7. When the filter element is illuminated with a

lamp after cleaning, the element must be re-
placed if small holes or thin portions are found
on it.
CZ335-1104107
Fig.5-36
Replacement of inner filter element
1. Remove the outer filter element [3] and then

remove the inner filter element [4].
4
2. Cover the air connector side with a clean
cloth to prevent dust from falling in it. 3
3. Clean the inside of the filter body and then

remove the covered cloth.
4. Install a new inner filter element [4] on the

connector. CZ215-1304005
5. Install the outer filter element [3] and Fig.5-37

straightly push it into by hand. Hold the outer
filter element gently and shake it up and down

and left and right in order to easily insert the

filter element.
6. Install the cover [2] correctly with the arrow

mark facing up and then buckle the clip (or
clamp) [1]. Check the gap between the air fil-
ter housing and the cover. Reinstall it if the
gap is too big. 2
NOTE：
• The inner filter element must not be used
again after being cleaned. Replace the inner 1
filter element while replacing the outer filter

element. CZ215-1304006
• If the inner filter element is not properly in-

Fig.5-38
stalled, but the outer filter element and the
cover have been installed, this will put the
outer filter element at risk of damage.
• Do not use counterfeit parts because they
may allow dust to enter due to insufficient
precision and cause damage to the engine.
5.9.5.2 Maintenance instructions of oil bath type air filter
Components of oil bath type air filter
• A Upper oil drum

• B Lower oil cake
• C Inner oil pan
• D Lower oil drum
Inspection of oil bath type air filter
• Check the appearance of the oil bath type

air filter and check the oil pan for damage
upon shift relief every day. If it is damaged,
please replace it in time. Fig.5-39
Cleaning and installation of oil bath type air
filter
• The oil bath type air filter should be in-

spected each time it is maintained (approxi-
mately every 500H). If the lower oil cake
has any signs of oil accumulation or

blockage, the oil bath type air filter should

be cleaned. The specific operation steps
are as follows:
1. Remove the oil drum D, and take out the

lower oil cake B and the inner oil pan C;
2. Pour the waste oil from the lower oil drum D

and the inner oil pan C into the waste collec-
tion tank, and remove the sludge deposited in
C and D. During operation, pay attention to
environmental protection and avoid environ-
ment pollution;
3. Clean the inner and outer oil cups with die-

sel (or other organic solvent);
4. Soak the lower oil cake B in a container

filled with diesel (or other organic solvent);
Fig.5-40
5. Dry the lower oil cake B naturally or dry it

thoroughly with compressed air;
6. Reassemble the inner oil pan C into the

lower oil drum D, and refill it with the waste oil.
See the table below for oiling amount;
Oiling amount for oil bath type air filter of large

excavator:
Oiling Grade of
Model
amount waste oil
SY365H 3.5 L
Same as the Fig.5-41
SY385H 5L
grade of
SY465H engine
(including 5L crankcase oil
scarifier)

SY500H
(including 3L
scarifier)
SY700\850H 4 L×2
7. Check the structure integrity of the upper

part of the assembly and the center pipe. In
case of breakage, cracking or loss, do
replacement;
Fig.5-42
8. Reassemble the air filter assembly.
Fig.5-43

5.9.5.3 Checking and adjusting belt tension of HVAC compressor
Inspection
With the finger force of approximately 58.8 N

(6 kgf), press the belt in the middle between
the drive pulley and the compressor pulley
and check that the deflection [A] should be 5-
8 mm (0.20 in-0.31 in).
Fig.5-44
Adjustment
• Loosen the bolts [1] and [2].

4
• Move the compressor [3] and the bracket 1
[4] together to adjust the belt tension.

• Position the compressor [3]. And then tight-
en the bolts [1] and [2].
• Check the belt tension again after
adjustment. 2
3
NOTE：
CZ215-1104019
1) Check whether each pulley is damaged,
Fig.5-45
and check whether the V groove and V belt
are worn. In particular, ensure that the V
belt does not contact the bottom of the V
groove.
2) If any of the following occurs, please con-
tact the dealer authorized by SANY in your
region to replace your belt.
• The fan belt is already extended, with lit-
tle margin for adjustment.
• Any cutting or crack is found on the belt.
• Abnormal slipping occurs or a squeaking
sound is heard.
3) After installing a new V-type belt, readjust it
after being used for 1 h.

5.9.5.4 Lubricating swing bearing
WARNING
• It is dangerous to fill grease on the gear
ring of the swing bearing. It is strictly pro-
hibited to fill grease while it is rotating.
1. Lower the work equipment to the ground,

shut off the engine and then pull the safety
lock lever to the “lock” position.
2. Fill grease to both grease fittings while the

machine is in a stable state.
3. Start the engine, pull the safety lock lever to

the “unlock” position, lift the bucket 20 to 30
mm above the ground, turn the machine 90°, CZ335-1104065
and fill grease by following the steps 1 and 2.

Fig.5-46
4. Repeat the operation for 2 times according

to the step 3 to finish grease filling.
NOTE：
• Grease is used to prevent twisting at the con-
nections and noise.
• Fill grease if any part becomes inflexible or
produces noise after used for a long time.
• When filling grease, wipe away the old
grease that has been squeezed out.
• Special care shall be taken to wipe away the
old grease at all positions, and sand or dust
getting into the grease may cause wear of
the rotating parts.
abnormal
• Check whether the pipe clamps of the hy-

draulic system are lost or deformed, or
whether the bolts are loosened. Any pipe
clamp, if lost or deformed, shall be

replaced. Any bolt, if loosened, shall be

tightened to the standard torque.
• Check whether the clamps at the oil return
rubber hoses of the hydraulic system and
the T-shaped clamps at the suction rubber
hoses of the main pump are loosened.
Tighten them to the standard torques if they
are loosened. Replace them immediately if
they are deformed or damaged.
5.9.6.1 General
Maintenance task scheduled for every 100

and 250 hours should be carried out
simultaneously.
5.9.6.2 Checking the level of grease in swing pinion and add grease
• Prepare a dipstick.
1. Remove the bolts [1] (2) on the upper part

of swing frame, then remove the lower cover
[2].
CZ335-1104068
Fig.5-47

2. Insert the dipstick [3] into the grease

through the inspection and adjustment holes,
and check whether the grease level [S] of the A 3
part where the pinion passes is at least 14mm
(0.6 in). Add grease if it is less than such
value. S
3. Check whether the grease is opalescent. If

so, it has been contaminated. Please contact
your Sany Heavy Machinery authorized deal-
er for replacement. CZ335-1104069
Total grease amount: 35L (9.24US gal) Fig.5-48
4. Install the cover [2] with bolts [1].
CZ335-1104070
Fig.5-49
5.9.6.3 Replacing the oil in engine oil pan, and replace the oil filter element
WARNING
• When the engine has just stopped, the hot
parts and oil may cause burns. Be sure to
wait for cooling down and then start the
operation.

• Oil pan capacity: see Capacity Table on the

page 5-11.
• Prepare a filter element wrench
1. Remove the bottom cover plate from the

bottom of the machine, then place an oil con-
tainer under the drain valve [P] to allow oil to
flow into the container through a clean cloth.
2. Open the drain valve on the bottom of the P

engine oil pan by the drain cock in the acces-
CZ335S-1103057
sories box in order to drain the oil. After drain-
ing, screw off the drain cock and put it away. Fig.5-50
Fig.5-51

the machine, then turn the filter element [1] to
the left with filter element wrench to remove it.
4. Clean the filter element base [2], fill the new

filter element with clean oil through the outer
ring hole, apply oil (or a thin layer of grease)
to the sealing surface and thread of the filter
element, and then install the filter element on
the filter element base.
NOTE： Fig.5-52
Check whether there is old seal on the filter el-
ement base [2], for fear of leakage.

5. When installing, contact the sealing surface

with the sealing surface of filter element base
[2], and then tighten 3/4-1 turn.
6. After replacing the filter element, open the

engine hood and add oil through filler to the
level between H and L on the dipstick. L H
7. Turn off the engine after a short time of idle

running. Check the oil level again to ensure it CZ335-1103131
is between L and H.
Fig.5-53
For details, see "Check the oil level in oil pan"
on the page 4-63.
8. Install the bottom cover.
CAUTION
• Please purchase original oil from the Sany
authorized dealer so that the oil qualify can
realize replacement cycle of 500 hours.
5.9.6.4 Replacing fuel primary filter element
WARNING
• After the engine is shut down, all parts are
hot. Do not replace the filter until these
parts are cooled.
will be generated in the fuel piping system.
• Replace the filter at least 30 seconds after
the engine is shut down when the internal
pressure has been reduced.

NOTE：
• The original Sany fuel filter element is a spe-
cial filter with efficient filtration capacity.
Therefore, when replacing the filter element,
it is necessary to use original part.
• Use of other parts may cause dust or dirt
contamination, resulting in faulted injection
system. Therefore, alternative parts are not
recommended.
• It is even more important to protect the fuel
system against dirt during inspection or
maintenance. If there is dust on the part, it
should be rinsed with oil.
• Prepare a container to hold fuel discharged
• Prepare a filter wrench

the machine.
2. Put an appropriate container under the fuel

pre-filter to catch the fuel discharged. Close
the cut-off valve [F] in fuel line to prevent leak-
age during the replacement of filter element.
3. Loosen the drain valve [1] to remove all the

water and sediment in transparent housing
[2], as well as the fuel in filter element.
4. Unscrew the upper cover [3], lift the filter el- Fig.5-54
ement, and replace the new filter element and
the corresponding O-ring.
5. After replacing the O-ring of upper cover,

tighten the upper cover. When installing, apply
oil on the sealing surface, contact the sealing
surface with the sealing surface of filter base
closely, then tighten 1/4-1/2 turn.
NOTE：
If the upper cover is tightened excessively, the
O-ring will be damaged, resulting in leakage.
If it is not tightened sufficiently, fuel will leak
from the gap of O-ring. To prevent such prob-
lems, it must be tightened to the specified
angle.
6. Check whether the drain valve [1] is firmly

tightened.
7. Discharge air after the filter element [3] is

replaced. For discharging method, see "Re-
place fuel fine filter element".
8. After replacing the filter element, start the

engine and let it run for 10 minutes at low idle
speed.
Check the sealing surface of filter base and

the position where the upper cover is installed
for any leakage. If so, check whether the filter
element is properly tightened.
If oil still leaks, repeat steps 1-5 and remove

the filter element. If the sealing surface shows
any damage or foreign matter, replace with a
new one.
5.9.6.5 Replacing fuel secondary filter and fine filter element
WARNING
• After the engine is shut down, all parts are
hot. Do not replace the filter until these
parts are cooled.
will be generated in the fuel piping system.
• Replace the filter at least 30 seconds after
the engine is shut down when the internal
pressure has been reduced.
• The original Sany fuel filter element is a

special filter with efficient filtration capacity.
Therefore, when replacing the filter ele-
ment, it is necessary to use original part.
• Use of other parts may cause dust or dirt
contamination, resulting in faulted injection
system. Therefore, alternative parts are not
recommended.
• It is even more important to protect the fuel
system against dirt during inspection or

maintenance. If there is dust on the part, it

should be rinsed with diesel.
Prepare a container to hold fuel discharged.
Prepare a filter element wrench.
1. Open the right access door.
2. Put the fuel container under the filter

element.
3. Loosen the drain valve [1] to remove all the

water and sediment in transparent housing
[3], as well as the fuel in filter element. Then
tighten the drain valve [1]. Fig.5-55
4. Turn the filter cylinder clockwise with filter
element wrench [2] to remove it.
5. Clean the filter element base, apply a thin

layer of oil on the sealing surface of the new
filter cylinder, rotate it counterclockwise to the
sealing surface, and tighten 3/4 turn.
NOTE：
Do not add fuel to the fine filter cylinder.
6. Loosen the transparent housing [3] clock-

wise with filter wrench.
7. Replace the paper filter element.
8. Rotate the transparent housing counter-

clockwise to the sealing surface and tighten 1/
4-1/2 turn.
NOTE：
• Do not add fuel to the transparent housing or
the filter element.

Fig.5-56
9. After replacing the filter element, check

whether all drain valves are properly tight-
ened, then exhaust.
Follow the steps below to exhaust.
10.Fill the fuel tank with fuel to facilitate ex-

haust; insufficient fuel will result in prolonged
exhaust.
11.Open the cut-off valve on coarse filter inlet

pipe.
Fig.5-57
12.Loosen the top screw plug [A] of the fuel
fine filter mount on the engine, to connect the
fine filter outlet. The arrow points to the upper
hinge bolt.
13.Turn on the electromagnetic pump switch

[B] to start pumping fuel. Stop pumping fuel
until the pumped fuel converges into a stream
and is ejected forcibly after bubbles are
drained.
14.Tighten the bleed screw [A] to the torque of

34 Nm, turn off the electromagnetic pump
switch [B] and close the rain cap [C].

NOTE：
• If the fuel with bubbles is continuously
ejected for a long time (about 10 minutes)
during bleeding, check the joint surface of
the first two seals for air leakage.
• Do not operate the electromagnetic pump
when the engine is in normal operation, oth-
erwise it may cause damage to the pump.
• After the engine is running out of oil, operate
the electromagnetic pump or manual oil
pump in the same method to exhaust.
15.After replacing the fine filter cylinder, start

the engine and let it run for 10 minutes at low
idle speed. Check the sealing surface of the
cylinder for leaks. If oil leaks, check whether
the filter cylinder is properly tightened; if leak-
age still exists, remove the cylinder in steps 1,
2, and 4. If the sealing surface shows any sign
of damage or impurities, replace with new fil-
ter cylinder and install in Step 5.
5.9.6.6 Cleaning and inspecting radiator and cooler fins
WARNING
• If the compressed air, high pressure water,
vapor is directed towards the body or is
used to remove dust or dirt, there is a risk
of personal injury. Be sure to wear goggles,
dust covers or other protective equipment.
CAUTION
• When the compressed air is used for
cleaning, a certain distance shall be main-
tained to avoid damaging the radiator fins.
• In dusty workplaces, inspect the radiator
fins daily irrespective of maintenance
period.
1. Open the access door on the left side of the

machine.

2. Check the radiator and intercooler. If there

is dirt, dust and leaves, remove with com-
pressed air or high pressure water in the op-
posite direction of air flow.
NOTE：
For high pressure water, the hydraulic giant
shall have lower spraying pressure and set to
mist at a distance of about 30 cm from the ra-
diator fins. Otherwise, they may be deformed,
causing premature clogging and cracking.
CAUTION
• Do not use hard objects to remove dirt dur-
ing cleaning to avoid damaging the radiator
fins.
3. After cleaning, check the radiator fins for

deformation, holes and cracks. If yes, make
an immediate adjustment and replacement.
Check the rubber hose for cracks or aging, if
any, replace with a new one; check and tight-
en the hose clamp.
4. Remove the cover plate [5] under the radia-

tor and clear the soil, dirt and leaves that have
been swept to the outside.
5. Install the cover plate [5], lock the engine

hood and access door at the left of the Fig.5-58
machine.
5.9.6.7 Cleaning the ventilation/circulation filter of HVAC
WARNING
• When compressed air is used, the flying
dust may cause personal injury. Therefore,
be sure to wear goggles, dust covers or
other protective equipment.
The filter shall be cleaned once every 500

hours, or more frequently in dusty workplace.

If the filter is blocked, the air volume will be

decreased and the air conditioning unit will
make an abnormal noise.
Clean the internal air filter of HVAC

1
1. Remove the screw [1] from the sight glass
on the bottom of the left rear of the cab, and
then loosen the clamp nut [2] and remove the
internal air filter [3].
2. Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
dium. After rinsing with water, make it dry thor- CZ335-1104075
oughly prior to use. Replace the filter with a

Fig.5-59
new one each year. If the blocked filter cannot
be cleaned with air or water, replace with a
new one.
CZ335-1104076
Fig.5-60

Clean the external air filter
1. Open the cover [4] on the left rear of the

cab with the key to the ignition switch, then
open the cover [4] by hand, remove the fixing 4
nut [5], and take out the external air filter [6].
2. Clean the filter with compressed air. If the

filter is oily or dirty, flush it with neutral me-
dium. After rinsing with water, make it dry thor- CZ335-1104077
oughly prior to use. Replace the filter with a

Fig.5-61
new one each year. If the blocked filter cannot
be cleaned with air or water, replace with a
new one.
3. After cleaning, put the filter [6] in place,

tighten the nut [5], and close the cover. Lock 5
4
the cover with the key to the ignition switch,
6
then remove the key.
CZ335-1104078
Fig.5-62
NOTE：
The external air filter must be installed in the
correct direction. When installing, insert the S
long [L] end of the filter [6] into the filter box. If L
the short [S] end is installed first, the cover [4]

will not be closed.
6
4
CZ335-1104079
Fig.5-63

5.9.6.8 Checking the oil level in swing gearbox and refilling
WARNING
• When the engine has just shut off, the hot
parts and oil may cause burns. Do not op-
erate until they are cooled.
Fig.5-64
1. Pull out the dipstick [G] and wipe the oil with
a cloth.
2. Insert the dipstick [G] completely into the fil-

ter pipe.
L
CZ335-1204006
Fig.5-65

3. Pull out the oil dipstick [G] and check

whether the oil level is between [H] and [L].
4. If the oil level is not at [L] on the dipstick [G],

remove the cap of filler [F] and refill.
5. If the oil level exceeds [H] on the dipstick

[G], loosen the drain valve [P] and drain the
excess oil.
• If the oil level is too high, hydraulic oil may
leak. Please contact your Sany Heavy Ma-
chinery authorized dealer for inspection.
• Before draining oil, place a container under Fig.5-66
the drain valve.
6. After checking the oil level or refilling, insert

the dipstick [G] into the hole and install the
cap of filler [F].
5.9.6.9 Checking the oil level of travel gearbox and refilling
WARNING
oil may cause burns. No not operate until it
is cooled.
• If there is residual pressure in the box, the
oil or plug will burst out. Slowly loosen the
plug to release pressure.
• When loosening the plug, do not stand in
front of it.
1. During checking, place the machine on flat

ground with the oil drain plug [D] downwards.
Then turn off the engine and set the safety
lock level in "LOCK" position.
2. Remove the dust in hexagon socket head

plug with a suitable screwdriver to avoid
damage.
3. Remove the oil level plug [L] with wrench,

then check the quantity of oil and contamina-
tion. When the oil surface reaches the oil level
plug port, there is appropriate quantity of oil. If
Fig.5-67

insufficient, add specified quantity of oil

through oil level plug.
4. Before installing, clean the oil level plug [L]

with diesel.
5. Check the travel gearbox on the other side

in the same way.
5.9.6.10 Replacing hydraulic tank breather filter element
WARNING
• Before replacing the breather valve filter el-
ement, shut off the engine.
• The hot parts and oil may cause burns. Do
not operate until they are cooled.
1. Before disassembly, clean the top cover of

the hydraulic tank, especially the contami-
nants around the breather valve (as shown in
the figure). Remove the bolt [1] and the
breather valve protective cover [2]. The site
shall be kept away from fire and dust.
Fig.5-68
2. Unscrew the butterfly nut [3] of breather

valve, then pressure the exhaust valve to re-
lease the internal pressure.
3. Remove the fixing nut [4] and filter element

cover [5], then remove the filter element [6].
4. If the filter cover [5] has too many internal

contaminants, clean it with a soft brush, and
then replace the filter with a new one.
5. Install the filter element cover [5] and tight-

en the fixing nut [4].
Fig.5-69

NOTE：
• Tighten the fixing nut [4] to the specified tor-
que (10 to 14 N·m). It is forbidden to tighten
with brute force for sealing.
5.9.7.1 General
Maintenance task scheduled for every 100,

250 and 500 hours should be carried out
simultaneously.
5.9.7.2 Replacing hydraulic oil filter element
WARNING
• When the engine is shut off, the hot parts
and oil may cause burns. Do not operate
until they are cooled.
If the machine is equipped with hydraulic

hammer, the hydraulic oil will deteriorate fast-
er than the normal bucket operation. For
maintenance, see “Replace the hydraulic oil
and replace the hydraulic tank filter” on the
page 7-13.
1. Place the machine on solid and flat ground,

with the work equipment placed as shown in
the figure. Lower the work equipment to the
ground and shut off the engine.
CZ335-1104086
Fig.5-70


valve on the hydraulic tank, press the exhaust
button to release the pressure in tank.
Fig.5-71
3. Loosen 4 bolts and remove the lower cover

[2]. During disassembly, the cover will burst
out due to the action of spring [3]. Press and
hold the cover when removing the bolts.
4. Remove the spring [3] and valve [4], then

remove the filter element [5].
• Check the bottom of the filter tank and
remove the dirt if any. Be careful not to
let any dirt fall into the hydraulic tank.
5. Clean the removed parts with cleaning oil.
6. Install new filter element. Fig.5-72
7. Install valve [4] and spring [3].
8. Install the cover [2] in place, press and hold

the cover, then tighten the bolts to install the
cover.

9. Replace the drain filter element [6] on the

side of the hydraulic tank as described in
steps 3-8.
Fig.5-73
10.Replace the pilot filter [7].
11.To exhaust air, start the exhaust and let it

run for 10 minutes at low idle speed.
12.Stop the engine.
Fig.5-74
5.9.7.3 Replacing the oil in swing gearbox
WARNING
parts and oil may cause burns. Do not op-
erate until they are cooled.

• Oil filling quantity: 10.5 L
1. Place a suitable container under the drain

valve [P] below the machine to hold the
drained gear oil.
2. Loosen the drain valve [P] to discharge

gear oil completely. Then tighten the valve.
NOTE：
• If the gear oil flows out in fine thread, stop
discharging.
• Prior to discharging oil under low tempera- Fig.5-75
ture, rotate the work equipment to slightly in-
crease the oil temperature. Do not rotate the
work equipment during discharging to avoid
to damage.
3. Remove the cap of filler [F] and add a spe-

cific quantity of oil through the filler.
4. Check the oil level. For details, see “Check

the oil level in slewing mechanism case and
refuel” on the page 5-54.
5. After confirming that the filler cap is not

blocked, apply sealant to the thread of breath-
er valve, then install and tighten the cap.
Tightening torque: 2.7 N·m
NOTE： Fig.5-76
Incorrect installation of the oil filler cap may
lead to the leakage of rotary reducer gear oil.

5.9.7.4 Checking the cab door lock and the front window lock for fastening
1. Check the cab door lock body
Fig.5-77
2. Door lock latch
Fig.5-78
3. Cab windshield lock latches (each at the left

and right)
If it is found that the above parts are loose,

tighten in time to ensure the normal opening
and closing of cab doors and windows.
Fig.5-79

5.9.7.5 Checking the lubricating oil of cab door hinge and front window slide guide
and refill
Add grease through door hinge grease fitting

till it overflows.
Fig.5-80
Apply grease to the left and right slide guide

grooves of the front window.
Fig.5-81

5.9.7.6 Checking the rocker nut of wiper for looseness
Check the wiper nut during each routine main-

tenance of the machine. Tighten the loose nut
if any to ensure the normal operation of the
wiper.
Pull up the protective cover at the bottom end

of the wiper arm to check for any loose nut; if
any, tighten it with torque wrench (35 to 40
N·m) or conventional wrench.
Fig.5-82
5.9.7.7 Checking all fastening parts of the engine exhaust pipe clamp
Contact your Sany Heavy Machinery authorized dealer to check the pipe clamp between air
cleaner-turbocharger-aftercooler-engine for looseness.
5.9.7.8 Checking the fan belt tension and replace the fan belt
Check the fan belt tension. If the belt is cracked or damaged, replace with a new one. If you have
any question, please contact your Sany Heavy Machinery authorized dealer.
5.9.7.9 Checking the nitrogen pressure in accumulator (for hammer)
Check the accumulator and the special tool for nitrogen filling. Please contact your Sany Heavy
Machinery authorized dealer for inspection and nitrogen filling.
5.9.7.10 Adding grease into swing reducer
1. Turn off the engine and pull the safety lock control lever to LOCK position.
2. Add grease through the grease fitting of swing drive assembly until it overflows.
NOTE：
• Remove the old grease squeezed out during greasing.
• The grease fittings for some models are connected with rubber hoses where grease can be
added.

5.9.8.1 General
1. Maintenance task scheduled for every 100,

500 and 1,000 hours should be carried out
simultaneously.
5.9.8.2 Replacing the oil in final drive case
WARNING
• When the engine is shut off, the hot oil and
parts may cause burns. Do not operate un-
til they are cooled.
• If there is pressure in the case, oil or plug
will burst out and cause injury. Be sure to
loosen the plug slowly to release pressure
and do not stand in front of it.
Make-up capacity:
See "Capacity Table" on the page 5-11.
1. Place the machine on flat ground with the

oil drain plug [D] downwards,. Then turn off
the engine and set the safety lock level in
"LOCK" position.
2. Remove the dust in hexagon socket head

plug with a suitable screwdriver to avoid
damage.
3. Put an oil container under the oil drain plug

[D], slowly loosen the oil level plug [L] and oil
drain plug [D] to drain oil.
4. After the gear oil is completely discharged, Fig.5-83

clean the oil drain plug [D] with diesel and in-
stall it.
5. Unscrew the filler plug [F] and add the

specified quantity of gear oil through filler until
the oil flows out of the plug hole [L].
6. Before installing, clean the plug with diesel.

NOTE：
Check the O-ring of the plug. In case of dam-
age, replace it with a new one.
5.9.8.3 Cleaning hydraulic tank strainer
WARNING

valve on the hydraulic tank, press the exhaust
button to release the pressure in tank.
Fig.5-84
2. Loosen 4 bolts and remove the cover [2].

Then the cover will burst out under the action 2
of spring [3]. Press and hold the cover when 3
removing bolts. 4
3. Hold and lift the top of the rod [4], then re-
5
move the spring [3] and strainer [5].
4. Remove all dirt on strainer [5], then rinse

with cleaning oil. If the strainer is damaged, 6
replace it with a new one.

CZ425-1104042
5. During installation, fix the strainer [5] on the
projection [6] of the tank and assemble it. Fig.5-85
6. When assembling, fix the spring [3] with the

convex part at the bottom of the cover [2],
then tighten with bolt.

5.9.8.4 Checking the nitrogen pressure in accumulator
WARNING
• As the accumulator is filled with HP nitro-
gen, improper operation will cause explo-
sion, resulting in mechanical damage and
personal injury.
• Keep away from fire. Do not collide or roll
the accumulator to avoid any shock.
• The gas in the accumulator must be re-
leased completely during handling. Please
contact your Sany Heavy Machinery au-
thorized dealer for doing this.
NOTE：
If the accumulator is filled with nitrogen at low
pressure continuously, it is difficult to release
the residual pressure in hydraulic circuit in
case of mechanical failure.
Functions of accumulator
The accumulator stores the pressure in con-

trol oil circuit. The control oil circuit works
properly to complete the following actions
even if the engine is turned off:
• The work equipment can be lowered under
the effect of self-weight by joystick.
• The pressure in hydraulic circuit can be
released.
Fig.5-86

Check the functions of accumulator
CAUTION
• First check whether there is any person or
obstruction in the surrounding area.
Check the nitrogen filling pressure according

1.5m
to the following steps:
1. Place the machine on a solid and flat

ground. CZ335-1104095
2. Keep the work equipment 1.5m (4 ft 11 in) Fig.5-87

from the ground, i.e. the maximum working ra-
dius, with arm fully extended, bucket com-
pletely turned over.
Complete steps 3 to 5 within 15 seconds.
As the pressure in accumulator gradually

drops when the engine is shut off, the check
must be done immediately after the engine is
shut off.
CC13031404
3. Keep the work equipment at the maximum
working radius, then turn the ignition switch to Fig.5-88
[OFF] and turn off the engine.
5. Set the safety lock control lever to “unlock"

position, and lower the work equipment to
ground by joystick.

6. If the work equipment is lowered to the

ground under the effect of self-weight, the ac-
cumulator is normal.
If the work equipment cannot be lowered or

suspended, the pressure in hydraulic circuit
accumulator may have dropped. Please con-
tact your Sany Heavy Machinery authorized
dealer for inspection.
7. After following the above steps, set the

CZ335-1104099
safety lock control lever to the “LOCK” posi-
tion and turn the ignition switch to [OFF] Fig.5-89
position.
Method for releasing pressure in control oil

circuit
1. Lower the work equipment to the ground.

Complete steps 4 to 6 within 15 seconds.
The pressure in accumulator gradually drops

when the engine is shut off. Therefore, the
pressure must be released as soon as the en-
gine is turned off.
CC13031403
Fig.5-90
3. Stop the engine.
4. Turn the ignition switch to [ON] position.

ON
OFF
STA
T
HEA
RT
CC13031804
Fig.5-91

5. Set the safety lock control lever on the “un-

lock” position, then operate the work equip-
ment joystick forward, backward, left and right
to release the pressure in control oil circuit.
6. Set the safety lock control lever on the

“lock” position and turn the ignition switch to
OFF position.
Fig.5-92
5.9.8.5 Replacing the oil in hydraulic tank
WARNING
• When removing the oil suction cap, pres-
sure the exhaust button of breather valve
to release the internal pressure.
If the machine is equipped with hydraulic

hammer, the hydraulic oil will deteriorate fast-
er than the bucket operation. For mainte-
nance, see “Replace the hydraulic oil and
replace the hydraulic tank filter” on the page
7-13.
Refilling quantity: See "Capacity Table" on the

page 5-11. Prepare a handle (for 36 mm sock-
et wrench).
1. Remove the bolts on the bottom cover

plate, and then remove the bottom cover
plate.
2. Rotate the upper mechanism so that the

drain plug at the bottom of the hydraulic tank
is located in the middle of the tracks on both
sides.
Fig.5-93

3. Retract the arm and bucket cylinder, then

lower the swing arm so that the bucket teeth
are in contact with the ground.
4. Place the safety lock control lever on “lock”

position and shut off the engine.
5. Remove the suction port cap [F] on the

upper part of the hydraulic tank.
6. Place an oil container below the drain plug

and use handle to remove the drain plug [P].
Check the O-ring on drain plug [P]. Replace
the damaged O-ring if any. After draining all
oil, tighten the drain plug [P].
NOTE：
Be careful not to splash the oil on yourself
when removing the drain plug [P].
7. Add a specified quantity of hydraulic oil Fig.5-94

through oil suction port [F]. Check whether the
level is between H and L of the dipstick.
• For details on applicable hydraulic oil, see
"Recommended fuel, coolant and lubricat-
ing oil" on the page 5-9.
• For details on check for oil level, see
“Check the oil level in hydraulic tank” on the
page 4-61.

5.9.8.6 Replacing the engine coolant and cleaning the inside of cooling system
WARNING
• When the engine is just turned off, the
high-pressure hot coolant in radiator may
cause burns if the radiator cover is re-
moved for discharging. After it is cooled,
slowly turn the cover to release pressure.
• When starting the engine for cleaning, set
the lock lever to the lock position to prevent
the machine from moving.
• The coolant is flammable and shall be kept
away from open flames.
• Be careful not to splash the coolant on
your body. If splashed into eyes, flush with
plenty of water and see a doctor
immediately.
• It is strictly forbidden to discharge the cool-
ant to sewers or the surface of the earth.
When replacing the coolant, please con-
tact your Sany Heavy Machinery author-
ized dealer.
Clean the inside of water radiator fins and re-

place coolant
1. Place the machine on flat ground, then turn

the ignition switch to [OFF] position to shut
down the engine.
2. When the cooling water is so cooled that

the radiator cover can be touched by hand,
slowly turn the radiator cap [1] until it contacts
with the stopper to release pressure, then re-
move it.
Fig.5-95

3. Remove the bottom cover plate under the

radiator, then place a container under the
drain valve [2] to hold coolant. 2
Open drain valve [2] at the bottom of the radi-

ator to drain coolant.
4. After draining the coolant, close drain valve

[2] and add running water and radiator clean-
ing agent. When the radiator is filled, start the
engine and let it run at low speed until the
CZ335-1104012
temperature rises to at least 90℃ (194 ℉),
then keep running for about 10 minutes. Fig.5-96
5. Shut off the engine and open the drain

valve [2] to drain water. Then flush the cooling
system with clean water until the discharged
water is clean to help remove rust and
deposits.
6. Close the drain valve [2], slowly add speci-

fied quantity of coolant until it overflows from
filling port.
7. Let the engine run for about 5 minutes at

low speed followed by 5 minutes at high
speed to drain the air in coolant. (At this time,
the radiator cap shall be opened)
8. Check the coolant level again. Appropriate

supplements may be made when necessary.
9. Turn off the engine, add water to the filling

port after about 3 minutes, and then tighten
the radiator cap.
10.Install the bottom cover plate.
Cleaning the hydraulic oil radiator fin

internally
1. Remove the hydraulic oil radiator fin before

cleaning and rinse on clean rinsing table.
2. Use the same brand of hydraulic oil, avia-

tion kerosene, gasoline, and diesel for
cleaning, then blow with air pump.

3. Do not use cotton, linen and chemical fiber

after cleaning to prevent the system from
being polluted by the falling fiber.
NOTE：
• The radiator shall be internally clean during
the whole rinsing process.
• The recommended cleaning medium are the
same brand of hydraulic oil, aviation kero-
sene, gasoline, and diesel successively.
5.9.8.7 Checking alternator
Please contact your Sany Heavy Machinery

authorized dealer to inspect alternator.
If the engine is started frequently, check the

alternator every 1,000 hours.
5.9.8.8 Checking and adjusting engine valve clearance
Special tools are required for inspection and

maintenance. For this, please contact the au-
thorized dealer of Sany.
5.9.9.1 General
Maintenance task scheduled for every 100,

250, 500, 1,000 and 2,000 hours should be
carried out simultaneously.
5.9.9.2 Checking water pump
Check whether there is water or oil leakage

around the water pump. If you have any prob-
lem found, contact your Sany Heavy Machi-
nery authorized dealer for disassembly,
repairing, or replacement.
5.9.9.3 Checking starter motor
Contact your Sany Heavy Machinery author-

ized dealer to check the starter motor.

If the engine is started frequently, check the

starter motor every 1,000 hours.
5.9.9.4 Replacing accumulator
Replace the accumulator every 2 years or

4,000 hours, whichever comes first.
WARNING
• As the accumulator is filled with HP nitro-
gen, improper operation will cause explo-
sion, resulting in mechanical damage and
personal injury.
• Keep away from fire. Do not collide or roll
the accumulator to avoid any shock.
• The gas in the accumulator must be re-
leased completely during handling. Please
contact your Sany Heavy Machinery au-
thorized dealer for doing this.
If the operation continues when the accumula-

tor is degraded, the pressure in hydraulic cir-
cuit will not be released in case of mechanical
failure. Please contact your Sany Heavy Ma-
chinery authorized dealer to replace
accumulator.
Fig.5-97

5.9.9.5 Checking the high pressure pipe clamp for looseness, and the rubber for
hardening
Fig.5-98
Check whether there is loose bolt on the high pressure pipe clamps (5) between supply pump and
fuel spray nozzle through observation and touching. If you have any problem, please contact your
Sany Heavy Machinery authorized dealer to replace parts.
5.9.9.6 Checking the operation of compressor
Check the following two items:
1. Whether the compressor and magnetic clutch are opened/closed when the HVAC switch is
turned on/off.
2. Whether the clutch or compressor makes abnormal noise.

If you have any problem, contact your Sany Heavy Machinery authorized dealer for disassembly,
repairing, or replacement.
5.9.10.1 General
Maintenance task scheduled for every 100, 250, 500, 1,000, 2,000 and 4,000 hours should be car-
ried out simultaneously.

5.9.10.2 Replacing high pressure pipe clamp
Please contact your Sany Heavy Machinery authorized dealer to replace the engine high pressure
pipe clamp.
If the machine runs up to 10,000 hours cumulatively, please contact your Sany Heavy Machinery
authorized dealer for maintaining the whole machine.


SY500H Hydraulic Excavator Troubleshooting
Troubleshooting
6 Troubleshooting ..............................................................................................................6-1
6.1 Special Instructions...............................................................................................................6-3
6.2 Preparations before Troubleshooting.................................................................................6-4
6.2.1 Inspections before Troubleshooting .........................................................................6-4
6.2.2 Precautions during Troubleshooting ........................................................................6-5
6.2.3 Precautions in Circuit Troubleshooting ....................................................................6-7
6.2.4 Precautions for Handling Hydraulic Components ..................................................6-7
6.2.5 Towing........................................................................................................................ 6-10
6.3 Engine Faults.......................................................................................................................6-11
6.3.1 Faults Diagnosis Table for Engine ..........................................................................6-11
6.3.2 High Water Temperature ......................................................................................... 6-16
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure) ........................... 6-17
6.3.4 Fuel Run-Out ............................................................................................................ 6-18
6.3.5 Engine Kick-Back ..................................................................................................... 6-19
6.4 Electrical System Failure .................................................................................................. 6-19
6.4.1 Faults Diagnosis Table of Electrical System ........................................................ 6-19
6.4.2 Display Monitor......................................................................................................... 6-23
6.4.3 Battery........................................................................................................................ 6-25
6.4.3.1 General............................................................................................................... 6-25
6.4.3.2 Removal and Refitting of Battery.................................................................... 6-26
6.4.3.3 Battery Charge .................................................................................................. 6-27
6.4.3.4 Start Engine with Auxiliary Wire...................................................................... 6-27
6.5 Hydraulic System Failure .................................................................................................. 6-30
6.6 Other Common Faults ....................................................................................................... 6-34

Troubleshooting SY500H Hydraulic Excavator
WARNING

6.Troubleshooting
6.1 Special Instructions
Situations described below, if occurred during
operation, are normal and in line with industry
standard, and thus please feel relieved to use.
1. You misunderstand an unavailable function

as a fault due to unfamiliarity with the features
of the machine (For example, the product is
not applicable to a altitude higher than 4km)
2. Stalling or black smoke occurs but the en-

gine is proved by the field test in the normal
operating range, i. e. the FSNs at instantane-
ous load and steady load are not greater than
4.5RP and 1.5RP respectively at an ambient
temperature below 30℃.
3. Excessive consumption of engine oil and

fuel occurs but turn out in the normal range
specified by the manufacturer in the field test.
4. Poor operation stability, grade ability, offset

travel and slow movement occurs due to your
unskilled operation and unfamiliarity with
working condition, but all the parameters are
proved by the field test in the normal range
specified by the manufacturer. (e.g., the tail of
the counterweight is up, grade ability is great-
er than 35°, etc.)
5. Unusual noise comes up in process of oil

return of the hydraulic system (such as unusu-
al noise in oil return and from pipelines), but it
is checked that the hydraulic system is normal
and the return oil filter is free of without impur-
ities as iron chips, cooper chips and aluminum

chips such that no affect will be exerted to the

normal operation of the device.
6. Common phenomena in the industry, such

as discoloration or blackening of piston rod,
reverse or automatic movement of cylinder,
and start difficulty of engine in chilly winter
days.
6.2 Preparations before Troubleshooting

6.2.1 Inspections before Troubleshooting
Judgment
Inspection Item Measures
Standard
1. Confirm fuel level and type — Refuel
2. Check the fuel for foreign matters — Clean and drain
3. Check the hydraulic oil level — Refuel
4. Check the hydraulic oil filter screen — Clean and drain
Lubri
5. Check oil level of upper structure — Refuel
cating
oil, 6. Check the engine oil level (oil pan oil
— Refuel
coolant level)
7. Check the coolant level — Add coolant
8. Check blockage of air cleaner — Clean or replace
9. Check the hydraulic oil filter element — Replacement
10. Check oil level of the final drive case — Refuel
1. Check the looseness and corrosion of
— Tighten or replace
battery terminals and wires
Electric
equip — Tighten or replace
alternator terminals and wires
ment
— Tighten or replace
starter motor terminals and wires
— Repair it
Hydraul 1. Check for abnormal noises and odors
ic 2. Check for oil leakage — Repair it
devices 3. Exhaust air inside — Exhaust
Electrici 1. Check the battery voltage (with engine 20-30V Replacement
ty and shut down)
electric 2. Check the battery electrolyte level — Refill or replace it

Judgment
Inspection Item Measures
Standard
equip 3. Check for discolored, burnt or peeled
— Replacement
ment wires
4. Check for falling clamps or hanging wires — Repair it
Remove the
5. Check whether the wire is wet (check
— connector and
connectors or terminals carefully)
blow it dry
6. Check whether the fuse is fused or
— Replacement
corroded
7. Check the alternator voltage (with the After running for a
engine running under the condition over few minutes:27.5~ Replacement
half throttle) 29.5V
8. Check the working noise of battery relay
— Replacement
(turn the switch between ON/OFF)
6.2.2 Precautions during Troubleshooting
CAUTION
• Park the machine on the horizontal ground, and confirm the function of safety pin, cushion block
and parking brake.
• During the collaborative operation, the signal shall be strictly unified and no irrelevant personnel
can be allowed to be close to it.
• If the radiator cap is removed when the engine is hot, hot water will be sprayed and cause burn-
ing, so maintenance shall be carried out after the engine is cooled down.
• Do not touch any hot parts or hold any rotary parts
• Always dismantle the negative terminal [-] first.
• When removing the internal oil pressure, water pressure or air pressure plug or cap, release
the internal pressure first.
• When installing the measuring equipment, ensure that the connection is correct.
• The purpose of fault diagnosis is to accurately determine the root cause of the faults and expedi-
tiously fix them and prevent their recurrence.
• During the fault diagnosis, to know the structure and function is of great importance.
• In order to conduct effective fault diagnosis, turning to operators to get a general knowledge of
the possible fault causes is also one of the shortcut for fault diagnosis.
1. Do not disassemble parts immediately during fault diagnosis. If parts are disassembled immedi-
ately, it may cause:
• The parts that are disassembled are irrelevant to the fault, or the parts have been disassembled
unnecessarily.

• The fault cause cannot be found out.

This will waste labor, parts, or oil and grease, while losing the user or operator’s trust in the
product.
Therefore, during fault diagnosis, it is necessary to check in advance and make fault diagnosis
according to the specified procedures.
2. Issues to be asked from users or operators:

• Are there any other unreported problems?
• Was there any abnormality before the fault appeared?
• Did the fault come up suddenly or following some signs?
• Under which circumstance the fault occurs?
• Was the machine repaired before the fault occurred?
• When was the machine repaired?
• Did this fault once appear?
3. Check other inspection items.

• Check the engine oil level.
• Check whether the oil leaks from the pipes or the hydraulic devices.
• Check the lever travel.
• Check the spool travel of the control valve.
• Other daily maintenance items can be inspected from the appearance, so only those deemed
necessary can be checked.
4. Confirm the fault

• Confirm the fault, and determine whether it is a true fault, whether there are problems in use and
operation, etc.
• When the machine is operated and the fault phenomenon reoccurs, no inspection or measure-
ment which will make the problem more serious shall be carried out.
5. Troubleshooting
• Conduct the inspections and tests according to item 2~4 to narrow the scope of fault causes,
then identify the faulty point according to the fault diagnosis flow chart.
• The basic process of fault diagnosis is as follows:
1) Start with the easy problem
2) Start with the possible problem
3) Check other relevant content.
6. Method of eliminating root cause of fault

• Even if the troubleshooting is done but the root cause is not eliminated, the same fault will occur
again. Therefore, it is necessary to find out the cause of the fault and eliminate the root cause.

6.2.3 Precautions in Circuit Troubleshooting
1. Always turn off the power before disconnecting or connecting the connector.
2. Check if all related connectors are correctly inserted plugged before fault diagnosis.
• Disconnect or connect the related connectors for several times for checking.
3. Always connect all the disconnected connectors before transferring to next step of operation.
• When the power is turned on with connectors disconnected, undesired abnormal indication will
occur.
4. When circuit fault diagnosis (measurement of voltage, resistance, connectivity or current) is

undergoing, related wires and connectors should be moved for several times and the meters read-
ings checked to be unchanged.
• If the readings change, contact failure may exist in the circuit.
6.2.4 Precautions for Handling Hydraulic Components
The most common fault cause is the sludge

(foreign matter) in the hydraulic circuit due to
the pressure increase and accuracy improve-
ment of hydraulic components. Special care
must be taken when adding hydraulic oil or
disassembling or assembling hydraulic
components.
1. Working environment
Avoid adding hydraulic oil, replacing the filter

or repairing the machine in the rain or strong
wind or a dusty place.
2. On-site disassembling and maintenance

operations
On-site disassembly and maintenance of hy-

draulic components may cause ingress of
ZX215-1000023
dust. It is also difficult to check the perform-
ance after repair, so you’d better replace with Fig.6-1
an assembly unit. Disassembly and mainte-
nance of hydraulic components shall be car-
ried out in a specially prepared dust-proof
workshop, and the performance shall be
checked by special test equipment.

3. Adding hydraulic oil
When filing the hydraulic oil, do not let oil

sludge or dust mix in. Always keep the filter el-
ements and their surrounding areas clean with
the use of sanitary pumps and oil containers.
The use of oil cleaning device is a more effec-
tive way to filter the oil sludge accumulated
during storage.
ZX215-1000025
4. Change the hydraulic oil under high
temperature Fig.6-2
Hydraulic oil or other oil is easy to move when
kept warm. Besides, sediments may be easily
expelled from the oil circuit together with oil.
Therefore, it is best to replace the oil while
hot. During replacement, drain the used hy-
draulic oil as much as possible. (Drain from
hydraulic oil tank; and drain from the filter and
the drain plug in the oil circuit.) The impurities
and sediments in the used oil, if any, will be
mixed with the new oil and thereby shorten
the useful life of hydraulic oil.
5. Flushing
When disassembling and reassembling the

device or changing the oil, remove the impur-
ities, sediments and old oil in hydraulic lines.
Normally, twice flush is needed: use flushing
oil for primary flushing, and designated hy-
draulic oil for secondary flushing.
Fig.6-3

6. Cleaning
The sediments and impurities in the hydraulic

lines need to be cleaned after repairing the
hydraulic components (pump, control valve,
etc.) or during the operation of the machine.
Oil cleaning device can clear up fine particles
(about 3 μ), and can effectively clean the oil
lines without dismantling the built-in filter of
the hydraulic components. ZX215-1000027
Fig.6-4

6.2.5 Towing
WARNING
• Always check whether the rope for traction
have enough strength to tow the machine, A
otherwise accidents may happen.

B
• In the process of towing, do not use rope
with breakage [A], decreased diameter [B]
C
or twist [C], in case the rope would be
broken.
• Always wear protective gloves to handle CZ335-1102063
the rope.
Fig.6-5
• Don’t tow the machine on a slope.
• In the process of towing, do not stand be-
tween the towing machine and the towed
machine.
• Operate the machine slowly, and do not
apply load suddenly to the rope.
Make sure to tow the machine under the maxi-

mum capacity.
• If the excavator is trapped in the mud and
cannot be driven out by it own power, or the
CZ335-1103216
if excavator is used for towing other heavy
object, it is allowed to use the rope as the Fig.6-6
right picture shows.
• Put wooden blocks or other protective ma-
terials under the contact site of the rope
and the machine to prevent abrasion for
both.
• Keep the rope horizontal and in the same
direction with the track frame.
• Tow machine be to the desired repairing
place with a speed less than 1 km/h. Pre-
vent long-distance towing.
CZ335-1103217
• Never tow the machine except in
emergency. Fig.6-7

6.3 Engine Faults

6.3.1 Faults Diagnosis Table for Engine
When a fault occurs, please conduct inspections according to the table below, and contact Sany
authorized dealer to carry out repairs.
Fault content Fault Analysis Measures

● Please charge or change the
● Power run-out of battery
battery
● Disconnection, looseness and
● Please clean the corroded place
corrosion of battery cables
The starter
● Fuse short-circuit ● Please replace the fuse
fails to fire or
rotate with ● Failure of the ignition switch or ●Please replace the ignition switch
difficulty starting relay or starting relay
●Please repair or replace the
● Failure of the starter motor
starter motor
● Please replace the engine oil
●High viscosity of engine oil
with proper viscosity
● Fuel run-out ● Please refuel and eliminate air
● Low starting pressure of fuel ● Please adjust or replace the fuel
Engine injector injector
start ● Please operate following the
failure ● Wrong starting operation
correct starting steps
● Please discharge the air in the
● Air mixed into the fuel system
fuel system
● Please replace the element or
The starter ● Fuel filter occlusion
cartridge of the fuel filter
starts
properly ● Please clean or replace the
● Air cleaner occlusion
element of the air cleaner
● Please repair or replace the
● Clutch slip
clutch
● Looseness of clamps for fixing
air suction rubber hose to the ● Please fasten the clamp
turbocharger
● Cracking of air suction rubber ● Please replace the air suction
hose of the turbocharger rubber hose
● The idle speed is too low ● Power run-out of battery
Engine stop after
starting ●Please replace the element or
● Fuel filter occlusion

●Please clean or replace the

● Failure of low idle speed ● Please repair or replace the low
control system idle speed control system
● Leakage or clogging of fuel
● Please overhaul the fuel system
system
● Please discharge the air in the
● Air in fuel system
fuel system
● Water in fuel system ● Please replace the fuel
● Fuel filter element occlusion
Unstable low idle speed
● Failure of fuel injection pump related parts of the fuel injection
pump
● Improper adjustment of valve ● Please adjust the valve
clearance clearance
● Leakage at cylinder gasket,
wear of cylinder liner, piston ring
sticking or cracking, improper ● Please replace the related parts
alignment of valve and valve
seat
● Fuel filter occlusion
● Water in the fuel ● Please replace the fuel
● Please clean or replace the
● Please repair or replace the fuel
● Failure of fuel transfer pump
transfer pump
●Low starting pressure of fuel ● Please adjust or replace the fuel
injector, and poor injection effect injector
Underpower ● Please repair or replace the
● Failure of fuel injection pump related parts of the fuel injection
pump
● Exhaust gas leaking from the ● Please repair or replace the
exhaust system related parts
● Air leaking from the intake
system ● Please replace the turbocharger
● Turbocharger assembly assembly
damaged
● Exhaust pipe blocked ●Please clean the exhaust pipe

● Improper adjustment of valve

●Please adjust the valve clearance
clearance
● Weakening or breakage of
● Please replace the valve spring
valve spring
seat
● Insufficient coolant ● Please add coolant
● Slippage of fan belt due to
● Please replace fan belt
looseness or cracking
● Cooler damaged or cooler ● Please replace cooler cover or
core blocked clean the cooler core
● Water pump damaged
water pump
Engine overheating ● Coolant leakage due to ● Please repair or replace the seal
damage of cylinder head or/and cover
cylinder block seal cover
● Thermostat damage ● Please replace the thermostat
● Cooling system blocked by ● Please remove the foreign
foreign matters matters in the cooling system
●Improper adjustment of fuel ● Please adjust the fuel injection
injection timing timing
● Water in the fuel ● Please replace the fuel
● Please adjust the fuel injection
● Fuel injection timing delay
timing
White smoke seat
● Turbocharger assembly failure ● Please repair or replace
● Failure of oil seal, damage of ● Please replace the valve oil seal,
valve stem and valve guide valve and valve guide
● Wear, breakage or improper ● Please replace the piston or
setting of piston ring reposition it properly
● Cylinder liner scratched or
● Please replace the cylinder liner
worn
Black smoke ● Air cleaner occlusion

● Improper adjustment of fuel ● Please adjust the fuel injection
●Fuel dripping due to damaged
outlet valve of fuel injection ● Please replace the outlet valve
pump
● Excessive injection of the fuel ● Adjust the amount of fuel
injection pump injection
● Fuel leakage
related parts of the fuel system
● Improper adjustment of low
●Please adjust the low idle speed
idle speed
●Improper adjustment of fuel ● Please adjust the fuel injection
● Fuel dripping due to damaged
● Please replace the outlet valve
outlet valve of fuel injection
High fuel consumption
● Air leaking from the intake- ●Please repair the intake-side of
side of the turbocharger the turbocharger
● Turbocharger assembly ● Please replace the turbocharger
damaged assembly
clearance clearance
● Weakening or breakage of
● Please replace the valve spring
valve spring
seat
● Please replace with suitable
● Unsuitable engine oil
engine oil
● Please adjust the amount of
High oil consumption ● Engine oil excess
engine oil
● Engine oil leaking from oil seal ● Please replace the oil seal and/
and/or gasket or gasket

● Please follow the correct steps in

● No preheating operation
operation
● Failure of oil seal, and wear of
● Please replace the related parts
valve stem and valve guide
● Wear, breakage or improper ● Please replace the piston or
setting of piston ring reposition it properly
● Cylinder liner scratched or
● Please replace the cylinder liner
worn
● Low engine oil level ● Please refill engine oil
● Improper viscosity of engine ● Please use lubricant of proper
oil viscosity
● Engine oil leaking from oil seal ● Please replace the oil seal and/
and/or gasket or gasket
● Fuel filter element occlusion
Low engine oil pressure cylinder of the fuel filter
● Relief valve sticking and/or by- ● Please replace the spring of
pass valve spring weakening safety valve and/or by-pass valve
● Please clean the strainer of the
● Strainer of oil pump blocked
oil pump
● Relevant parts of oil pump ● Please replace the related parts
abrasion of the oil pump
●Fitting looseness or damage of ● Please screw down exhaust pipe
the exhaust pipe fittings or replace the exhaust pipe
● Please tighten up the fuel
Air leakage ●Fuel injector looseness
injector and replace the gasket
noise
● Looseness of exhaust ● Please tighten up the exhaust
manifold fitting manifold fitting
Abnor
mal ● Cylinder gasket broken ● Please replace the cylinder liner
engine ● Please adjust the tension of the
noise ● Fan belt looseness
belt
● Cooling fan looseness ● Please tighten the cooling fan
Continuous
● Wear or damage of water ● Please replace the bearing of the
noise
pump bearing water pump
clearance clearance

6.3.2 High Water Temperature
WARNING
• Do not open the cover of the cooler when
the water temperature is excessively high,
and if you do so, the boiling water or steam
may splash and cause scald. When the
temperature of the coolant goes down,
please pad a thick cloth on the cover and
open it slowly.
CAUTION
• Do not stop the engine immediately. Other-
wise the rising temperature will burn the
engine parts
• Please add water slowly in multiple times
in case the sudden injection of cool water
cracks the engine.
When the reading of the water thermometer

exceeds 100℃ and the indication light is on, it
means the water temperature of the cooler ex-
ceeds the limit. Please stop the device, and
keep the engine running at a speed a little
higher than idle speed to cool down. When
the pointer of the water thermometer goes to
the center and the High Temperature Light is
off, stop the engine, then do as follows.
1. Check whether there is coolant leakage of

the cooler rubber hose.
2. Check the amount of coolant. Please refill

coolant when it is insufficient.
3. Check whether there is object in front of the

cooler.
4. Coolant leakage or constant water tempera-

ture out-of-gauge indicates cooling system
failure.
6.3.3 Engine Oil Pressure Abnormality (Low Engine Oil Pressure)
When the engine is just started, oil pressure

gauge indicates high pressure. After adequate
preheating operation, please check the oil
pressure once more.
When the indicator warns abnormal oil pres-

sure. Please stop the machine, and shut down
the engine immediately and do as follows.
CAUTION
• Please shut down the engine immediately
for continuing operation may bring damage
to the engine.
1. Check whether the engine oil leaks.

1
2. Check the amount of the engine oil, and re-
fill if insufficient.
• Take out the engine oil dipstick [1], and
clean the engine oil with cloth.
• Dip the dipstick completely into the engine
oil, then take out slowly.
• If the engine oil trace on the dipstick is be-
tween H and L, the oil amount is normal.
• Refill the engine with oil timely if it is insuffi- CZ215-1105004
cient. Replace the engine oil if it is obviously

Fig.6-8
unclean.
• Put the dipstick back to the slot after
examination.
3. When the engine oil is of normal amount

but the warning light still indicates abnormal
pressure, please contact Sany authorized
L H
dealer to repair.
CZ335-1103131
Fig.6-9

6.3.4 Fuel Run-Out
When fuel runs out, remember to add fuel be-

fore starting the engine, and discharge air
from fuel system.
WARNING
• Neither use lighter nor smoke during
bleeding. Otherwise it may lead to fire and
cause serious accident.
• Splashed engine oil or fuel may catch fire
in case of heat source or cause slipping
accident, so please clean up the splashed
engine oil and fuel at the exhaust pipe or
other places.
• Since the operation area is cramped, be
careful not to get hurt by the surrounding
parts.
1. Loosen the bleed screw [C], and cover it

with cloth or something else. C
2. Turn on the electromagnetic pump switch

[2] to deliver fuel continuously, until there is no
more bubbles coming out of the bleed screw.
3. Tighten the bleed screw [C] after making

sure no bubbles come out.
4. Tighten the bleed screw and turn off the

electromagnetic pump.
14111903
5. After the air is completely discharged, clean Fig.6-10

up the splashed fuel, then start the engine.
6. Please confirm if there is fuel leakage.
WARNING
• Do not operate the electromagnetic pump
when the engine is in normal operation, for
fear of damage to the pump.

6.3.5 Engine Kick-Back
WARNING
• When the engine kicks back, please shut down the engine immediately, otherwise the engine
will burn in a few minutes or serious accident may occur, and the exhaust gas from the air
cleaner may also cause a fire.
When the engine kicks back, following situation will come up.
• Harsh impacting noise at the beginning of running.
• Black smoke from the air cleaner.
• Low engine oil pressure warning on the display.
Please check and clean the air cleaner and rubber hose after stop, and if any abnormality is
found, replace the affected part with a new one.
6.4 Electrical System Failure

6.4.1 Faults Diagnosis Table of Electrical System
When a fault occurs, please conduct inspections according to the table below, and contact Sany
authorized dealer to carry out repairs.

● Charge or replace the
● Low battery
battery
● Internal fault of ignition switch ● Replacement
● Repair or replace the
● Pilot switch fault
part
● Starter motor fault
part
The engine cannot be started
● Wire harness open circuit ● Inspect and repair
● Fuse fault ● Replacement
● Short circuit of wire (grounding
● Inspect and repair
fault)
● Internal fault of alternator
part
● Starter relay fault ● Replacement
● Open circuit of wire harness ● Inspect and repair
Irregular fluctuation of engine ● Internal fault of sensor ●Replacement
speed ●Short circuit of wire (grounding
fault)


● Internal fault of controller ●Replacement
The complete vehicle can't be ● Battery relay fault ●Replacement

powered off ● Surge diode breakdown ● Replacement
● Boom lifting signal fault ● Inspect and repair
● Boom lowering signal fault ● Inspect and repair
● Arm digging signal fault ● Inspect and repair
● Arm unloading signal fault ● Inspect and repair
It runs idly automatically and ● Bucket digging signal fault ● Inspect and repair
doesn’t work ● Bucket dumping signal fault ● Inspect and repair
● Swing signal fault ● Inspect and repair
● Traveling signal fault ● Inspect and repair
● Accessory signal fault ● Inspect and repair
● Controller fault ● Replacement
● Failure of glow plug fuse ● Replacement
The preheating function is ● Failure of glow plug relay ● Replacement
disabled ● Short circuit of wire (grounding
fault)
● Safety lock switch fault
part
●Short circuit of wire (grounding
No equipment works ● Inspect and repair
fault)
● Internal coil failure of pilot
● Replacement
lockout solenoid valve
● Sensor fault ● Replacement
● Short circuit of wire harness
Slow and powerless rising ● Inspect and repair
(grounding fault)
movement of the boom
● Harness open circuit ● Inspect and repair
Slow and powerless ● Inspect and repair
(grounding fault)
movement of the arm
Slow and powerless
movement of the bucket


(grounding fault)
Slow and powerless traveling ● Inspect and repair
(grounding fault)
movement
● Fuse fault ● Replacement
● Wire disconnection fault ● Inspect and repair
The display is blank ● Short circuit of wire (grounding
fault)
● Display screen fault ● Replacement
● Resistance fault ● Replacement
The display has no display ● Short circuit of wire (grounding
fault)
● Fault of display or controller ● Replacement
● Fault of high/low speed traveling
● Replacement
solenoid valve
The high/low traveling speed ● Inspect and repair
●Wire disconnection fault
function is disabled
fault)
●Coolant temperature sensor fault ● Replacement
Incorrect temperature display
of engine coolant ● Short circuit of wire (grounding
fault)
● CAN bus abnormality ● Inspect and repair
● Oil level sensor fault ● Replacement
The display of fuel level is
inaccurate ● Inspect and repair
fault)
● Short circuit of wire and 24 V ● Inspect and repair
The wiper doesn’t work ●Internal fault of wiper motor
part


fault)
● 5 V power supply fault
part
The display of arm digging ● Signal wire open circuit ● Inspect and repair
pilot pressure is inaccurate
● Signal wire short circuit ● Inspect and repair
part
The display of arm unloading ● Signal wire open circuit ● Inspect and repair
part
The display of boom lifting ● Signal wire open circuit ● Inspect and repair
part
The display of boom drop pilot ● Signal wire open circuit ● Inspect and repair
pressure is inaccurate
● Signal wire short circuit ●Inspect and repair
part
The display of bucket digging ● Signal wire open circuit ● Inspect and repair
part
The display of bucket
unloading pilot pressure is ● Signal wire open circuit ● Inspect and repair
inaccurate ● Signal wire short circuit ● Inspect and repair
The display of swing pilot ● Repair or replace the
pressure is inaccurate part


● Signal wire open circuit ● Inspect and repair
part
Incorrect display of travel pilot ● Signal wire open circuit ● Inspect and repair
pressure
6.4.2 Display Monitor
Conduct fault diagnosis & analysis according to the DTC on the display. As for the description to
DTC, please refer to relay-related description in the "Operation" section.
DTC Fault content Activating conditions

E101 Internal fault of controller RAM/EEPROM error; Task pause detected
Controller internal temperature Temperature inside the controller sustains at over
E102
abnormality 110℃ or -40℃ for 10s
Sensor power output abnormality detected and
E103 Sensor power abnormality
lasting for 1s.
Storage error (GPS locking
E104 GPS lock memory error
storage)
CPU processing abnormality detected;
unrecoverable memory error detected; I2C
E105 CPU error
communication pause detected; Program writing
abnormality; parameter writing abnormality.
PGN receipt pause (1s) or invalid SPN data
E401 CAN bus abnormality
detected
Input signal is beyond the threshold range
E501 Throttle knob abnormality (0.25~4.75V), which lasts for a period longer than
the setting time (0.2s).
Hydraulic oil temperature sensor Voltage except acquired voltage (0.25~4.75V)
H401
abnormality lasts for 0.2s
P402 Fuel level sensor abnormality
H101 P1 pump pressure abnormality Input signal is beyond the threshold range
H102 P2 pump pressure abnormality (0.25~4.75V), which lasts for a period longer than
the setting time (0.2s).
Arm unloading pilot pressure
H204
abnormality


Arm digging pilot pressure
H203
abnormality
Boom lifting pilot pressure
H205
abnormality
Boom lifting pilot pressure
H206
abnormality
Bucket unloading pilot pressure
H202
abnormality
Bucket digging pilot pressure
H201
abnormality
Swing pilot pressure
H209
abnormality
Left travel pilot pressure
H207
abnormality
Right travel pilot pressure
H208
abnormality
Pressure abnormality of large
H113
hydraulic oil chamber of boom
Cooling pump pressure
H114
abnormality
P1 pump proportional valve
H105
current abnormality
P2 pump proportional valve
H108
current abnormality
Boom priority 2 proportional
H312 Current of proportional solenoid valve coil is
valve current abnormality
above the upper threshold (1.8 A), which lasts for
Arm 2 converging solenoid valve
H318 a period longer than the setting time (1 s); current
abnormality
deviation of proportional solenoid valve coil is
Cooling pump proportional valve above the threshold (±0.1 A).
H321
current abnormality
Boom 2 converging solenoid
H324
valve abnormality
Boom priority proportional valve
H309
current abnormality
Traveling high and low speed ON/OFF solenoid voltage abnormality.
H315
solenoid abnormality When the command is ON, the voltage stays
Alarm lamp (light) relay below the threshold (15 V), which lasts for a
E703 period longer than the setting time (0.1 s);
abnormality


E702 Starter motor relay abnormality
Shutdown delay relay
E701
abnormality
when the command is OFF, the voltage stays
Alarm lamp (sound) relay
E704 above the threshold (3 V), which lasts for a
abnormality
period longer than the setting time (0.1s).
Pilot locking solenoid valve
H327
abnormality
P605 Fuel filter relay abnormality
H402 hydraulic oil overheating Hydraulic temperature above 90℃
E201 Low power voltage Voltage <18V, delay = 10s
E202 High power voltage Voltage >32V, and delay = 10s.
ECM sends alarm signal of low engine oil
P101 Too low engine oil pressure
pressure.
P301 Cooling water overheating ECM sends water alarm signal of overheating.
P401 Low fuel level Fuel level ≤10%, delay = 10s.
P501 Air filter blocked Air filter on-off action blocked.
Water separator water level too Water separator high water level switch is
P601
high actuated.
P606 Fuel filter system abnormality Fuel filter system alarms on-off action.
P100 Engine abnormality Engine fault
6.4.3 Battery
6.4.3.1 General
2
1
1
2
CZ335-1103219
Fig.6-11

WARNING
• It is dangerous to charge the battery when
the battery is mounted in the machine. Al-
ways disassemble the battery from the ma-
chine before charging.
• When checking or handling the battery, al-
ways turn the ignition key to OFF to shut
down the engine.
• When handling the battery, always wear
goggles and rubber gloves.
• When disassembling the battery, discon-
nect earthing cable (negative terminal [-])
first. When mounting, first mount the posi-
tive terminal[+]. Be careful not get the tool
touching the positive terminal and chassis;
otherwise, fire hazard may ensue.
• Loose contact of terminal may generate
sparks, causing explosion.
• When disassembling or assembling termi-
nals, test which is the positive terminal [+],
and which is the negative terminal[-].
6.4.3.2 Removal and Refitting of Battery
• Before disassembling battery, always disas-

semble earthing cable (normally connected
to negative terminal [-]) first.
• If the tool touches between the positive ter-
minal and chassis, fire disaster may occur.
• Use clamp to fix the battery when changing
battery.
• Order of connecting battery wire: first con-
nect the battery positive wire, then connect
the battery negative wire.
• Order of disconnecting battery wire: first
disconnect the battery negative wire, then
disconnect the battery positive wire.

6.4.3.3 Battery Charge
When charging the battery, any improper op-

eration may lead to explosion. Always operate
according to the battery and charger specifi-
cations, and do as follows:
• Adjust the charger voltage to match the bat-

tery. If the wrong voltage is selected, the
charger may go overheating, and cause
explosion.
• Connect the charger positive terminal [+] to
the battery positive terminal [+], and con-
nect the charger negative terminal [-] to the
battery negative terminal [-]. Always fix the
clamp.
• Adjust the charging current to the 1/10 of
CZ335-1103220
the rated battery capacity; in case of fast
charging, tune down the charging current Fig.6-12
under rated battery capacity. Overcurrent
may lead to electrolyte leakage or vaporiza-
tion, which will cause battery on fire or
exploding.
• If the battery electrolyte freezes, do not
charge the battery or use different power
supply to start the engine. Otherwise it will
ignite the battery electrolyte and result in
battery explosion.
6.4.3.4 Start Engine with Auxiliary Wire
Connect and disconnect auxiliary wire

WARNING
• When connecting the wires, do no let the
positive terminal [+] contact the negative
terminal [-].
• Avoid the contact between normal machine
and failed machine, so as to prevent
sparks being generated around the battery
igniting the hydrogen released from the
battery.
• Be careful not to make mistakes in con-
necting auxiliary wires. At the end of con- Fig.6-13
nection (i.e. connection with upper frame),
sparks will come up, so you need to con-
nect the wire as far away from the battery
as possible. (But always avoid work equip-
ment since it is not good conductor)
• When removing the auxiliary wire, be ex-
tremely careful not to let the wire clamps
touch each other or contact the chassis.
NOTE：
• The starting system adopts 24V voltage, is
normally supplied by two 12V battery in
series.
• The specification of auxiliary wire and clamp
should conform to the battery specification.
• The battery should have the same capacity
with the engine which it will start.
• Check whether the wires and clamps are
broken or corroded.
• Make sure the wires and clamps fixed well.
• Check whether the safety lock control lever
of the two machine both at the “LOCK”
position.
• Check whether all levers stay at the middle.

Auxiliary wire connection
Keep the ignition switches of normal machine A

and failed machine at OFF. Connect the auxili-
2 1
ary wire according to the number order 3
marked on the picture.
1. Connect the clamp of auxiliary wire [A] to D C

the positive terminal [+] of the failed machine 4
B
battery [C]. E
CZ335-1103222
2. Connect the other clamp of auxiliary wire
[A] to the positive terminal [+] of the normal Fig.6-14
machine battery [D].

[B] to the negative terminal [-] of the normal
machine battery [D].

[B] to the failed machine swing frame [E].
Start the engine
WARNING
• No matter when the machine is operating
normally or has failed already, always
check the machine, and keep the safety
lock control lever at the “LOCK” position,
and check whether all levers stay at the
neutral position.
1. Make sure that the clamps and battery ter-

minals connected firmly.
2. Start the engine of a normal machine and

run it at high idle speed.
3. Turn the ignition switch of the failed ma-

chine to the “START” position and start the
engine.
If the engine fails to start in first time, try again
2 minutes later.

Auxiliary wire disconnection
After the engine starting, disconnect the auxili-

A
ary wires in the reverse order of connecting
3 4
them. 2
1. Disassemble a clamp of auxiliary wire [B]

from swing frame of the failed machine [E]. D C
1
2. Disassemble the clamps of auxiliary wire B E
[B]from the battery [D]negative terminal [-] of

CZ335-1103223
the normal machine.
Fig.6-15
3. Disassemble the clamps of auxiliary wire
[A] from the battery [D] positive terminal [+] of
the normal machine.
4. Disassemble the clamps of auxiliary wire

[A] from the battery [C] positive terminal [+] of
the failed machine.
6.5 Hydraulic System Failure
• When failures occur, please conduct examination according to the table below, and contact
Sany authorized dealer to carry out repairs.
• Set the working mode as S Mode and engage the 10th gear to conduct fault diagnosis.

● Main relief valve improperly
● Replace
adjusted or fails
The work equipment moves
slowly, or it has low traveling and ● Pilot relief valve failure ● Replace
rotation speed ● Regulator failure ● Repair, replace
● Piston pump failure ● Inspect and repair
● Pilot pump relief valve failure ● Replace
Work equipment, travel or swing
● Hydraulic pump failure ● Inspect and repair
failure
● Coupling failure ● Inspect and repair
● Feeding with
● Hydraulic oil level decrease
hydraulic oil
The hydraulic pump has unusual ● Replace suitable
● Hydraulic oil of poor quality
noise hydraulic oil
● Hydraulic oil tank top cap air
● Clean up or replace
breather blocked


● Hydraulic oil tank strainer
● Clean up or replace
blocked
● Piston pump failure ● Inspect and repair
● Sensor failure ● Replace
Automatic idle speed failure ● Pilot valve failure ● Replace
● Controller failure ● Repair, replace
● Right pilot valve (boom oil line)
failure
● Pressure sensor failure ● Replace
● Boom control valve (spool)
● Repair, replace
failure
Slow boom movement ● Boom control valve (holding
● Repair, replace
valve) failure
● Boom control valve (safety valve
and refilling valve) failure or seal ● Repair, replace
failure
● Boom cylinder failure ● Repair, replace
● Left pilot valve (arm oil line)
failure
● Arm control valve (spool) failure ● Repair, replace
● Arm control valve (regeneration
Slow arm movement ● Repair, replace
valve) failure
● Arm control valve (safety valve
failure
● Arm cylinder failure ● Inspect and repair
● Right pilot valve (bucket oil line)
failure
● Bucket control valve (spool)
● Repair, replace
failure
Slow bucket movement ● Bucket control valve (holding
● Repair, replace
valve) failure
● Arm control valve (safety valve
failure
● Bucket cylinder failure ● Inspect and repair


● Pilot valve failure ● Inspect and repair
The single cylinder of the work ● Pressure sensor failure ● Replace
equipment has no movement ● Work equipment control valve
● Repair, replace
(spool) failure
● Work equipment cylinder failure ● Repair, replace
● Maintaining valve (boom, arm)
● Repair, replace
failure
The cylinder drift of the work ● Work equipment control valve
equipment is too large (safety valve and refilling valve) ● Repair, replace
seal failure
● Work equipment valve spool
● Repair, replace
failure
● Arm regeneration valve failure ● Repair, replace
The work equipment moves
slowly ● Control valve (safety valve and
● Repair, replace
refilling valve) failure
Other work equipment moves
when a single oil line has an ● Control valve seal failure ● Replace
overflow
Swinging or traveling speed
● Straight travel valve spool failure ● Repair or replace
decreasing obviously
● Travel pilot valve failure ● Repair, replace
● Pilot relief valve failure ● Replace
● Regulator failure ● Repair, replace
● Proportional solenoid stuck ● Repair, replace
The machine has off-tracking
during traveling ● Travel valve spool stuck ● Repair, replace
● Hydraulic swivel stuck ● Repair, replace
● Travel motor failure ● Repair, replace
● Travel pilot pressure sensor
● Replace
failure
● Pilot relief valve failure ● Replace
● Sensor failure ● Replace
Machine traveling slowly ● Travel control valve (spool)

● Repair, replace
failure
● Travel control valve (oil filing
● Repair, replace
valve) failure
● Travel motor failure ● Inspect and repair


● Travel pilot pressure sensor
● Replace
failure
● Travel control valve (spool)
● Repair, replace
failure
The machine is hard to turn or
powerless ● Travel control valve (oil filing
● Repair, replace
valve) failure
● Travel motor (safety valve)
● Repair, replace
failure
● Travel motor (check valve)
● Repair, replace
failure
● High speed switching solenoid
The traveling speed cannot be ● Replace
valve failure
shifted
● Travel base valve failure ● Repair, replace
● Travel motor safety valve failure ● Repair, replace
● Travel motor balance valve
It cannot travel (only on one side) ● Repair, replace
failure
● Pilot pressure sensor failure ● Replace
● Swing motor ● Inspect and repair
● Swing motor (safety valve)
Swing failure to left ● Adjust, replace
improperly adjusted or failed
and right
The ● Swing motor failure ● Inspect and repair
machine ● Swing mechanism failure ● Inspect and repair
cannot
● Pilot valve failure ●Repair, replace
swing
Swing failure in ● Swing control valve (spool)
● Repair, replace
single direction failure
● Swing motor (refilling valve) seal
● Replace
failure
● Swing motor ● Inspect and repair
Poor acceleration ● Adjust, replace
Slow swing performance or
slow swing ● Swing motor failure ● Inspect and repair
● Unclog or replace
● Brake control lines blocked
the lines


● Pilot valve failure ● Repair, replace
● Swing motor (pressure
● Repair, replace
Poor acceleration compensation valve) failure
performance in ● Swing motor (refilling valve) seal
single direction, or ● Replace
failure
slow swing
● Swing pilot pressure sensor
shuttle valve leakage on single ● Repair, replace
side
Overswing in two ● Adjust, replace
The directions
● Swing motor failure ● Inspect and repair
overrun is
too large ● Pilot valve failure ● Repair, replace
when swing ● Swing control valve (spool)
Overswing in single ● Repair, replace
stops failure
direction
● Swing motor (refilling valve) seal
● Replace
failure
● Swing pilot valve failure ● Repair, replace
The impact is too large when
● Rebound damping valve failure ● Repair, replace
swing stops
● Swing relief valve failure ● Repair, replace
● Back pressure valve failure ● Repair, replace
● Repair, replace
The unusual noise is too loud failure
when swing stops ● Swing motor (refilling valve)
● Repair, replace
failure
● Swing mechanic structure failure ● Inspect and repair
When applying ● Swing brake control lines failure ● Inspect and repair
swing parking brake ● Swing motor (parking brake) ● Repair, replace
Excessive
swing ● Swing control valve (spool)
● Repair, replace
hydraulic When applying failure
drifting swing parking brake ● Swing motor (relief valve) failure ● Repair, replace
failure ● Swing motor (refilling valve)
● Repair, replace
failure
6.6 Other Common Faults

● Looseness and unusual noise ● Check and tighten up
Noisy structural member
of fasteners again


● Increasing end clearance
● Adjust the clearance to
between bucket and arm due to
1mm
abrasion
● Deformation and weakness of
bucket tooth pin spring after
long-term use ● Replace the bucket
Bucket tooth dropping in operation
tooth pin
● Mismatching of bucket tooth
pin with tooth base
● Loose track ● Tighten the track
● Guide wheel running
Track twist under the excavator ● Sprocket running fast in front
slow in front on the
on the bumpy road
bumpy wheel
● Poor contact of electrics or
connector
● Blowing rate switch, relay or
Running failure of fan temperature control switch ● Repair or replace
damage
● Fuse breakage or low battery
voltage
● Obstacle at intake side ● Clean up
● Poor heat transfer due to
Small air volume with fan running blockage of evaporator or ● Clean up
normally condenser fin
● One of the fan impeller stuck
● Replace
or damaged
● Clutch engagement failure
because of broken line and ● Repair
poor contact in electric circuit
● Undertensioning of ● Adjust compressor belt
Failed or difficult running of compressor belt tension
compressor
● Coil breakage and failure of
● Replace clutch coil
compressor clutch coil
● Too much or too little ● Adjust the filling
refrigerant amount of refrigerant
● Coolant leakage ● Eliminate leaking point
Coolant (freezing medium)
shortage ● Add coolant as
● Coolant underfilling
appropriate
Readings of high and low ● When environment temperature is 30~50℃
pressure gauge in normal working ● High pressure reading: 1.47~1.67MPa(15~17kgf/cm2)
condition ● Low pressure reading: 0.13~0.20MPa(1.4~2.11kgf/cm2)


● Excessive opening width of ● Replace the expansion
Low expansion valve valve
pressure Frost attached on
● Poor contact of expansion ● Properly mount the
above the surface of low
valve sensing bulb sensing bulb
specified pressure pipe
value ● Excessive coolant inside the ● Drain some coolant to
system the specified amount
Both high and low
● Refill coolant to the
pressure below ● Coolant shortage
specified amount.
Low normal value
pressure Negative pressure
below ● Low pressure hose blocked, ● Repair the system,
sometimes indicated
specified expansion valve blocked by ice replace the liquid
on the low pressure
value or dirt reservoir if blocked by ice
gauge
Evaporator freeze ● Thermostat out of operation ● Replace thermostat
Frosting at inlet side of expansion ● Clean or replace the
● Expansion valve blocked
valve expansion valve
Expansion valve inlet side not felt ● Air leakage of expansion
● Replace the expansion
cold, but low pressure being valve sensing pipe or sensing
valve
negative sometimes bulb
● Drain away coolant,
● Air mixed into circulation
Both high and low vacuumize again, and
system
pressure above then add coolant
High
pressure normal value ● Drain coolant as
● Coolant overfilling
above the appropriate
specified ● Clean and unblock the
● Condenser blocked by dust
value Poor performance of condenser
condenser ● Check and replace
● Condenser fan damaged
condenser fan
Both high and low ● Repair, and refill with
● Coolant shortage
pressure below the refrigerant as specified
specified value,
High ● Low pressure pipeline ● Clean and replace
negative reading
pressure blocked and damaged failed part
sometimes shown on
below the
the low pressure
specified
gauge, and
value ● Internal failure of compressor ● Replace compressor
compressor and high
pressure pipe
overheated
Poor cooling effect due to warm ● Closing failure of heater valve ● Replace heater
air influence due to damage solenoid valve

SY500H Hydraulic Excavator Accessories and Options
Accessories and Options
7 Accessories and Options ...........................................................................................7-1

7.1 Safety precautions ................................................................................................................7-3
7.2 Hydraulic control component and line supporting accessories ......................................7-5
7.2.1 Position of components..............................................................................................7-5
7.2.2 Hydraulic lines .............................................................................................................7-6
7.2.3 Removal and installation of accessories .................................................................7-9
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter ..................................... 7-13
7.2.5 Long-term storage.................................................................................................... 7-14
7.3 Recommended accessory operation .............................................................................. 7-14
7.3.1 General ...................................................................................................................... 7-14
7.3.2 Hydraulic breaker ..................................................................................................... 7-15
7.3.3 Operation of hydraulic breaker............................................................................... 7-15
7.3.4 Forbidden operation................................................................................................. 7-17
7.3.5 Greasing of hydraulic breaker ................................................................................ 7-19
7.4 Quick coupler and control system.................................................................................... 7-20
7.4.1 Operation method of quick coupler........................................................................ 7-20
7.4.2 Precautions for safety operation of quick coupler ............................................... 7-22
7.5 Refueling system................................................................................................................ 7-23
7.5.1 Introduction to refueling system ............................................................................. 7-23
7.5.2 Composition of refueling system............................................................................ 7-24

Accessories and Options SY500H Hydraulic Excavator
WARNING

7.Accessories and Options

7.1 Safety precautions
Pay attention to safety while installing accessories or options on board. Please comply with the fol-
lowing precautions for selection, installation and use of accessories or options:
Precautions for selection
• Before installing accessories or options on board, please consult the agents authorized by Sany
Heavy Machinery Co., Ltd. Depending on the type of accessory or option, front guard, overhead
guard or other safety structures may be required to be installed on board additionally.
• Only accessories or options approved by Sany Heavy Machinery Co., Ltd. shall be installed.
Sany Heavy Machinery Co., Ltd. will take no responsibility for the accident, damage or malfunc-
tion caused by unapproved accessories or options.
Please read the Operation Manual carefully
• Before installing and using any accessories or options, be sure to read carefully and understand
the contents of the corresponding Operation Manual.
• If the Operation Manual was lost or damaged, you should ask the manufacturer of accessories
or the agents authorized by Sany Heavy Machinery Co., Ltd. for a new one.
Precautions for removal and installation
Ensure safety while removing and installing accessories or options. Please comply with the follow-
ing precautions:
• Remove and install the accessories or options in a flat and solid place.
• When the cooperative work between two or more persons is required, one should be the
commander and others follow his/her commands.
• Use the lift to carry the object over 25 kg. (The lift must be operated by qualified and experienced
staff with official license.) It is forbidden to stay under the lifted object.
• During removal and installation process, please don’t use the machine while any object is being
lifted. Please use a holder to avoid the object falling if necessary.
• Before removing some heavy parts, consider the effect of the removal on the balance of the ma-
chine. To prevent rollover, the machine may be supported before removal of some heavy parts,
if necessary.
• Ensure the accessories or options to be installed or removed ones are stable and would not turn
over.
• As for more details about removal or installation, please consult the agents authorized by Sany
Heavy Machinery Co., Ltd.

Precautions for use
Please keep in mind the following precautions while installing large or heavy accessories or
options.
• Before operation, please move the machine to a safe place for trial operation and make sure that
you have clearly known the movement, center of gravity and working range of the machine.
• Do not swing the machine if it is inclined; otherwise, the machine would be in the risk of turning
over.
• In the process of operation, make sure to keep a safe distance from the machine to the sur-
rounding obstacles. Please pay attention to the followings while installing heavy accessories or
options:
• The turning circle of heavy accessories or options may be large. Incorrectly calculating their
turning circle could cause a risk of hitting other objects. Please reserve a large space for rota-
tional motion.
• When the lifting process stops, the heavier the accessories or options are, the longer distance
they will move downwards under their dead weight. Therefore do not stop them at the lifting posi-
tion, but lower them down to the ground.
• Never swing, lower or stop the accessories or options abruptly to prevent the machine from turn-
ing over.
• Never extend or retract the boom cylinder abruptly to avoid machine rollover due to impact.

7.2 Hydraulic control component and line supporting accessories

7.2.1 Position of components
CZ335-1105001-1
Fig.7-1
[1] Ball valve [3] Control pedal

[2] Selector valve
Ball valve[1]
Ball valve is used for controlling the flow of hy-

draulic fluid.
Position[A]: FREE, hydraulic lines ON

A
Position[B]: LOCK, hydraulic lines OFF
When removing or installing accessories, ad-

just this valve to LOCK position.
B
CZ335-1105002
Fig.7-2

Selector valve [2]
Selector valve is used for switching the flow

direction of hydraulic fluid.
This valve should be set based on the se-

lected working mode, which must match the
installed accessories.
For more details about working mode switch-

ing, see “Hydraulic lines” in Page 7-6.
CZ335-1105003
Fig.7-3
Control pedal [3]
Control pedal is used for controlling accesso-

A
ries. When the forepart and rear-part of the
control pedal is depressed, the performance N
of the accessories is as follows:
• Hydraulic breaker B
Forepart of the pedal [A]: ON

Rear-part of the pedal [B]: OFF
NOTE： CZ335-1105004
As for other accessories, please consult the

manufacturers before installation to determine Fig.7-4
the operation of the pedal and accessories
before use.
7.2.2 Hydraulic lines
When the machine is equipped with a hydraulic breaker, the return lines must lead to the return fil-
ter directly. Therefore, do not use return lines except for in mode B. When the hydraulic breaker
pipeline is not pre-installed on the machine, if the user installs this pipeline by itself, the return pipe-
line must be provided with a filter. The pipeline of the hydraulic breaker and the filter must be veri-
fied by the agents authorized by Sany Heavy Machinery Co., Ltd, otherwise any subsequent
consequences shall be borne by the user.
The standard set pressure of the relief valve in the service valves has already been set when the
machine was delivered from the factory. When choosing Mode B, it is set as 20.6 MPa (210 kgf/
cm2); when choosing the hydraulic shear mode, it shall be set as 20.6 / 31.4 MPa (210 / 320 kgf/
cm2). Depending on the type of accessories, it may need to be adjusted. In case of that, please
contact the agents authorized by Sany Heavy Machinery Co., Ltd for adjustment.

Switching of hydraulic lines

• Depending on the type of accessories, set the working mode in the display screen in accordance
with the following standard.
• The set pressure of the relief valve in the service valves and the switch of the hydraulic lines is
specified as per the selected working mode.
Set pressure of relief

Accessories Working mode Hydraulic lines
valve in service valves
The hydraulic line
automatically forms at When delivered from
Accessories of No. 1
the point where the the factory:
hydraulic line, e.g. Mode B
return line doesn’t 20.6Mpa(210kgf/cm2,
hydraulic breaker
lead to the control 2980PSI)
valve.
When delivered from
the factory:
The hydraulic line 20.6/31.4 MPa (210/
Accessories of double automatically forms at 320 kgf/cm2)
acting hydraulic line, e.g. Mode S the point where the Note:
hydraulic shear return line leads to the When clamp operates:
control valve. 320 kgf/cm2
When clamp opens:
210 kgf/cm2
Switch between hydraulic breaker and general accessories

• When optional accessories are installed and Mode B is set as the working mode
1. The hydraulic line of the hydraulic breaker (No. 1 hydraulic line) forms.
2. Overflow valve is set to low pressure.

When delivered from the factory: 20.6 MPa (210 kgf/cm2)
• When optional accessories are installed and Mode S is set as the working mode
1. The hydraulic line of the hydraulic shear (double acting hydraulic line) forms.
2. Overflow valve is set to high pressure. When delivered from the factory: 31.4 MPa (320 kgf/
cm2)

Connection of hydraulic lines
When connecting accessories, please con-

nect the hydraulic lines as per the following
steps.
1. Check whether the ball valve is in LOCK po- A

sition [B].
• FREE: Hydraulic lines ON (the direction of
arrow is parallel to the length direction of B
the arm)
CZ335-1105002
• LOCK: Hydraulic lines OFF (the direction of
arrow is vertical to the length direction of Fig.7-5
the arm)
2. Remove the screw plugs [1] at the end of

the ball valve pipeline (one on the left and one
on the right).
NOTE：
Do not lose or damage the removed parts.
1
CZ335-1105005
Fig.7-6
3. After removing the screw plug [1], ask the

manufacturer of the accessory to connect the
hydraulic line of the accessory [2].
As for the dimensions of the connector and

2
the added accumulator, different manufac-
turers require different measures. Therefore
please contact the agents authorized by Sany
CZ335-1105006
Fig.7-7
Flow path of hydraulic fluid
The operation direction of the pedal and the flow path of hydraulic fluid are as shown below.
CZ335-1105007
Fig.7-8
When the forepart of the pedal is depressed, the hydraulic fluid will flow to the left pipeline of the
work equipment; when the rear part of the pedal is depressed, the hydraulic fluid will flow to the
right pipeline of the work equipment. (When a hydraulic breaker is installed, only the forepart of the
pedal works.)
7.2.3 Removal and installation of accessories
Removal of accessories
1. Lower down the work equipment to the

ground and shut down the engine.
2. Turn the ignition switch to [ON] position,

then set the safety lock control lever to "UN-
LOCK" position.
3. After finishing step 2, fully operate two joy-

sticks frontward, rearward, leftward and left-
CC13031404
ward in 15 seconds and step on the
accessory control pedal 2-3 times to release Fig.7-9
the internal pressure in the hydraulic lines.

4. Turn the safety lock control lever to “LOCK”

position.
CC13031403
Fig.7-10
5. The internal pressure in the hydraulic lines

will be released through the breather valve [F]
at the top of the hydraulic tank. F
To release all pressure, rotate and open the

butterfly nut of the breather valve [F] and
press the release button to release pressure.
CZ335-1105011
Fig.7-11
6. Check that the hydraulic fluid temperature

has declined, and turn the rotor of the ball
valve (installed at the outlet and inlet pipelines
at the side of the arm) to "LOCK" position [B].
arrow is parallel to the length direction of
A
the arm)
arrow is vertical to the length direction of
B
the arm)
CZ335-1105012
7. Remove the hose at the side of accessory.
Fig.7-12
Install the screw plugs at two outlets.

NOTE：
The screw plugs are used for avoiding incor-
rect operation of the accessories caused by
the entry of foreign matters. After correct in-
stallation of the screw plugs, the accessories
shall be preserved.
8. Pull out the mounting pins (at 2 points), re-

move the accessories and install the bucket.
As for more detail about installation steps of

the bucket, please see “Replacement of buck-
et” in Page 5-21.
9. After installing the bucket, check the fluid

level in the hydraulic tank.
CZ335-1105013
Fig.7-13
Installation of accessories
1. Remove the bucket.
2. Place the accessory horizontally, set pin

[A], and then use pin [B] to install the acces-
sory to the arm.
A
3. Lower down the work equipment to the

ground and shut down the engine. B
CZ335-1105014
Fig.7-14

4. Turn the ignition switch to [ON] position,

then set the safety lock control lever to "UN-
LOCK" position.
5. After finishing step 2, fully operate two joy-

sticks frontward, rearward, leftward and right-
ward in 15 seconds and step on the
accessory control pedal 2-3 times to release
the internal pressure in the hydraulic lines.
CC13031404
Fig.7-15
6. Turn the safety lock control lever to "LOCK"

position.
CC13031403
Fig.7-16
7. The internal pressure in the hydraulic lines

will be released through the breather valve [F]
at the top of the hydraulic tank. F
To release all pressure, rotate and open the

butterfly nut of the breather valve [F] and
press the release button to release pressure.
CZ335-1105011
Fig.7-17

8. Check that the hydraulic fluid temperature

has declined, and remove the screw plugs
from the outlet and inlet respectively. Pay at-
tention to avoiding any dust or dirt affixed to
the connection of the hose.
A
If the O-ring is damaged, replace it with a new
one.
9. Connect the hose at the side of the acces-

B
sory. During connection, check that the hy-
CZ335-1105012
draulic fluid flows in correct direction.
Fig.7-18
10.Set the rotors of the ball valves installed at
the inlet and outlet pipelines at the side of the
arm to FREE position [A].
arrow is parallel to the length direction of
the arm)
arrow is vertical to the length direction of
the arm)
11.After installing the accessory, check the flu-

id level of the hydraulic tank.
7.2.4 Replacement of hydraulic fluid and hydraulic tank filter
The operation of the hydraulic breaker will accelerate the pollution of the hydraulic system and the
degradation of hydraulic fluid. Therefore, compared with the machine equipped with the bucket,
the machine with hydraulic breaker requires frequenter replacement of hydraulic fluid and hydraul-
ic tank filter. Failure to observe this may cause damage to the hydraulic breaker, hydraulic pump
and other parts of the hydraulic system. Recommended replacement interval is as follows. (As for
the replacement method of the filter element and the hydraulic fluid, see the Section
“Maintenance”.)
Replacement interval (unit: hour)

Machine with hydraulic breaker Machine with general bucket
Hydraulic oil 600 1,500 or 2,000 or 4,000
Filter element 100 1000

NOTE：
• The data in the table above are based on the 100% operation time of the hydraulic breaker. When
the operation time of the hydraulic breaker declines, the replacement interval could be prolonged
as shown below.
• After continuous operation of the hydraulic breaker for 100 hours, the filter element must be
replaced.
Fig.7-19
7.2.5 Long-term storage
If the equipment will not be in use for a long time, please follow the steps below.
• Turn the ball valve to [LOCK ] position.
• Install the screw plug on the valve.
• Turn the lock pin to [LOCK] position. If no hydraulic breaker or general accessory is installed on
the machine, overheating or other issues may arise during operation of the pedal.
7.3 Recommended accessory operation

7.3.1 General
During operation of the hydraulic excavator

equipped with accessories, following specifi-
cations must be complied with.

NOTE：
The type of applicable accessories or the
model of special accessories depends on the
model of the hydraulic excavator. Therefore,
as for the selection of the related accessories,
please contact the agents authorized by Sany
7.3.2 Hydraulic breaker
Main purposes:
• Rock crushing
• Removal operation
• Road project
This accessory is widely used for removing

buildings, crushing road or slag, tunnel opera-
tion, rock crushing and the crushing operation
in quarry.
CZ335-1105016
Fig.7-20
7.3.3 Operation of hydraulic breaker
1. When conducting crushing operation, tightly

press the drill rod vertically on the surface of
the target object.
90°
90°
CZ335-1105017
Fig.7-21

2. When applying impact, press the drill rod on

the impact surface, leaving the forepart of the
lower structure about 5 cm (2 in) above the
ground, as shown on the right. Don’t leave the
machine more than that value above the
ground.
NOTE：
Don’t lift the excavator too high.
CZ335-1105018
Fig.7-22
3. During application of continuous impact to

the same surface, if the drill rod is unable to
pierce or crush the surface, change the im-
pact part and conduct crushing again on the
part near the edge.
CZ335-1105019
Fig.7-23
4. The piercing direction of the drill rod will

gradually be out of line with the direction of
the body of the hydraulic breaker. Adjust the R
bucket cylinder to align them.
CZ335-1105020
Fig.7-24

5. Consistently press the drill rod on the im-

pact surface properly to prevent the impact
without resistance.
CZ335-1105021
Fig.7-25
7.3.4 Forbidden operation
To ensure long service life and safe operation

of the machine, do not operate the machine
as the following.
• Do not operate all the cylinders to the end
of the stroke. Make sure to keep a distance
of about 5cm (2 in).
1. Accumulate the rocks and stones by the hy-

draulic breaker.
CZ335-1105022
Fig.7-26
2. Operate with swing force.
CZ335-1105023
Fig.7-27

3. Move the drill rod during application of

impact.
CZ335-1105024
Fig.7-28
4. Keep the drill rod horizontal or upward dur-

ing application of impact.
CZ335-1105025
Fig.7-29
5. Swing the drill rod when the rock has been

pierced.
CZ335-1105026
Fig.7-30

6. Pecking operation.
CZ335-1105027
Fig.7-31
7. Lift the machine away from the ground by

totally extending the bucket cylinder.
CZ335-1105028
Fig.7-32
7.3.5 Greasing of hydraulic breaker
Add grease to the hydraulic breaker on the

right place (as shown).
CZ335-1105029
Fig.7-33

NOTE：
• Incorrect greasing operation may cause ex-
cessive grease. As a result, soil and sand will
enter the hydraulic lines, such that, during
operation of hydraulic breaker, the hydraulic
parts will be damaged.
• Therefore, make sure to add grease to the
breaker kept in right position.
CZ335-1105030
Fig.7-34
CZ335-1105031
Fig.7-35
7.4 Quick coupler and control system

7.4.1 Operation method of quick coupler
1. Take out the safety shaft of the quick cou-

pler, as shown on the right.
Fig.7-36

2. Press the quick coupler switch [1] (self-re-

set type) on the left joystick to close the mov- 1
ing and fixed jaws slowly.
CZ335-1105033
Fig.7-37
3. Make the fixed jaw of the quick coupler

catch the bucket shaft [2] slowly, as shown on
the right.
2 3
CZ335-1105034
Fig.7-38
4. Extend the bucket cylinder and move the

moving jaw of the quick coupler towards the
bucket shaft [3] slowly.
2
3
CZ335-1105035
Fig.7-39

5. Allow the jaw of the quick coupler to get

stuck with the bucket shaft [3] totally.
6. Loosen the quick coupler switch to make

the quick coupler get stuck with the bucket
shaft, and conduct other operation.
7. After finishing installation, plug the safety

shaft again.
CZ335-1105036
Fig.7-40
7.4.2 Precautions for safety operation of quick coupler
1. Due to installation of the quick coupler, the

turning radius will be longer when the bucket
and other connecting parts are operating. It is
possible that these parts would collide with
the cab or the boom of the excavator. There-
fore please operate with care. Due to installa-
tion of the quick coupler, please retract the
bucket (with the bucket cylinder fully ex-
tended) before the arm???. Never operate the
bucket when the arm has been retracted to
the right position (with the arm cylinder fully CZ335-1105037
extended) to prevent collision with the boom.
Fig.7-41
2. Overload operation will damage the part

connected to the quick coupler and the exca-
vator, thus reducing the service life of the
machine.
CZ335-1105038
Fig.7-42

3. Do not exert pressure when the quick cou-

pler contacts the ground. Please check that
the quick coupler is connected to the bucket
or other part during operation.
CZ335-1105039
Fig.7-43
4. Moving a weight by the quick coupler is very

dangerous and may also reduce the service
life of the coupler.
NOTE：
If the installation of the quick coupler is neces-
sary, please consult the local agents author-
ized by Sany Heavy Machinery Co., Ltd. Be
sure to use the accessories designated by
Sany Heavy Machinery Co., Ltd. Otherwise,
Sany Heavy Machinery Co., Ltd will take no
responsibility for any malfunction or accident
caused by any unapproved accessories. Fig.7-44
7.5 Refueling system

7.5.1 Introduction to refueling system
SANY excavator may be equipped with refuel-

ing system as an optional configuration. The
system operates with the refueling pump as-
sembly. Being powered by the vehicle-
mounted battery, the refueling pump assem-
bly is free from the limits of the area and
power supply, thus having greatly enhanced
work efficiency, increased economic benefit
and reduced labor intensity.

The refueling volume of different types of ma-

chine is shown in the “Capacity table” in Page
5-11.
7.5.2 Composition of refueling system
• The refueling system of SANY large exca-

vator is mainly composed of: refueling 1 2
pump assembly (including related pipelines

and valves) and control switch.
• Open the battery box cover [1] to find the
3
control switch [2] and the refueling pump
[3].
CZ335S-1105001
Fig.7-45
The main part of the refueling pump [3] is as

shown on the right.
Main performance parameters of

refueling pump
Pump flow 46L/min
Rated voltage 24V
Rated speed 2800rpm
Connector thread
3/4'G
specification
CZ335S-1105002
Weight 3.5kg
Fig.7-46
Package dimension 215×120×160mm

www.sanygroup.com
Sany Heavy Machinery Co., Ltd.

Sany Heavy Machinery Industrial Park, Dongcheng avenue, Kunshan Economic
Development Zone, Jiangsu, China
P.C.: 215300
E-mail: [email protected]
Service hotline: 4008 28 2318 Tel: 4008 87 9318

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Quality Changes the World

Operation and Maintenance Manual

Operation and Maintenance Manual

Operation and Maintenance Manual-12-2015 1

2 Operation and Maintenance Manual-12-2015

Operation and Maintenance Manual-12-2015 1

2 Operation and Maintenance Manual-12-2015

We do not accept any responsibility for the following:

Responsibilities of our manufacturer

Responsibilities of customers or other authorized personnel concerned

Operation and Maintenance Manual-12-2015 1

Responsibilities of all the operation personnel

2 Operation and Maintenance Manual-12-2015

Operation and Maintenance Manual-12-2015 I

2.2.14.3 Fire caused by electrical wire......................................................................... 2-22

II Operation and Maintenance Manual-12-2015

2.3.3 Parking ........................................................................................................................ 2-44

Operation and Maintenance Manual-12-2015 III

4.2 Description of controls and instruments.............................................................................4-6

IV Operation and Maintenance Manual-12-2015

4.2.16.3 Operation of HVAC .......................................................................................... 4-52

Operation and Maintenance Manual-12-2015 V

4.3.11.4 Cab door on the slope ..................................................................................... 4-98

5.2.6 Filter element ............................................................................................................. 5-10

Operation and Maintenance Manual-12-2015 VII

5.9.6.10 Replacing hydraulic tank breather filter element ......................................... 5-61

VIII Operation and Maintenance Manual-12-2015

6.2 Preparations before Troubleshooting.................................................................................6-4

7 Accessories and Options ...........................................................................................7-1

Operation and Maintenance Manual-12-2015 IX

7.5 Refueling system................................................................................................................ 7-23

X Operation and Maintenance Manual-12-2015

Operation and Maintenance Manual-12-2015 1-1

1-2 Operation and Maintenance Manual-12-2015

Operation and Maintenance Manual-12-2015 1-3

1.2 Safety information

1-4 Operation and Maintenance Manual-12-2015

Examples of safety warnings

a. Examples of literal safety decals

To release pressure, loosen

Operation and Maintenance Manual-12-2015 1-5

b. Examples of graphic safety decals

Safety icons are graphic representations of

In the figure on the right, the safety icon above

1.3 Page description

Sany hydraulic excavator is designed for:

Please refer to the relevant part of this manual in detail.

The international system of units (SI) is used in this manual.

1-6 Operation and Maintenance Manual-12-2015

1.4.2 Directions of the machine

In this manual, the front, back, left and right

1.4.3 Running-in of new machines

Our machines are fully commissioned and

Be sure to carry out running-in within the initial

Be sure that you are fully aware of the content

After start-up, keeping the machine idling for 3

Avoid high-speed operation at heavy load.

Operation and Maintenance Manual-12-2015 1-7

1.5 Product information

1.5.2 Machine data plate